Foam article with enhanced properties

ABSTRACT

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application, titled “Foam Article with Enhanced Properties,” is acontinuation of U.S. Non-Provisional patent application Ser. No.17/195,161, filed Mar. 8, 2021, and titled “Foam Article with EnhancedProperties, which claims priority to U.S. Provisional Patent ApplicationNo. 62/987,329, filed Mar. 9, 2020, and titled “Foam Article withEnhanced Properties” and to U.S. Provisional Patent Application No.62/987,648, filed Mar. 10, 2020, and titled “Foam Article with EnhancedProperties” and to U.S. Provisional Patent Application No. 62/987,227,filed Mar. 9, 2020, and titled “Injection Molding System and Tooling”and to U.S. Provisional Patent Application No. 63/137,872, filed Jan.15, 2021, and titled “Injection Molding System and Tooling” and to U.S.Provisional Patent Application No. 62/987,224, filed Mar. 9, 2020, andtitled “Footwear Component Manufacturing System and Methods” and to U.S.Provisional Patent Application No. 63/042,324, filed Jun. 22, 2020, andtitled “Manufacturing Processes and Systems for Forming Footwear SolesUsing Recycled Thermoplastic Copolyester Recyclate” and to U.S.Provisional Patent Application No. 63/071,393, filed Aug. 28, 2020, andtitled “Manufacturing Processes and Systems for Forming Footwear SolesUsing Recycled Thermoplastic Copolyester Recyclate.” These applicationsare assigned to the same entity as the present application, and areincorporated herein by reference in the entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

TECHNICAL FIELD

The present invention relates to a foam article, such as a cushioningelement, such as a midsole for an article of footwear, having a numberof enhanced properties.

BACKGROUND

Foam articles, such as cushioning elements can be used in an article offootwear, apparel or sporting equipment. An article of footwear may bedesigned to accommodate a foot of a wearer performing variousactivities. One component of such articles of footwear is a cushioningelement, such as a midsole. The midsole provides cushioning, stabilityand/or structure to the article of footwear.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential elements of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter. The present invention is defined by the claims.

At a high level, aspects herein relate to a foam article, such as acushioning element for an article of footwear, apparel or sportingequipment. In some aspects, the article comprises a physically foamed,injection molded component, such as a midsole, having a number ofbeneficial physical characteristics. In some aspects, the physicallyfoamed article is the product of foaming a thermoplastic elastomermaterial using a physical foaming agent, or a combination of a physicalforming agent and a chemical agent. In some aspects, the articlecomprises a foam component, wherein the foam component has a foamvolume, wherein the foam volume includes a foam core and anintegrally-formed skin that encases the foam core, wherein both the foamcore and the skin comprise a single thermoplastic elastomer material.Optionally, the foam core can comprise a plurality of integrally formedand connected foam sub-volumes. These foam sub-volumes can form a seriesof integrally formed and connected portions of foam in the core, and aseries of concentric ridges on the exterior surface of the skin,typically which appear to extend radially outward from an injection gatevestige location. Striation bands may appear on the exterior surface ofthe skin, particularly near the perimeter of the foam article. The foamcore (including its sub-volumes and portions of foam) can have anopen-cell structure or a closed-cell structure. Additional components,such as solid molded components, can optionally be combined with thefoam component to form an article such as a sole structure for anarticle of footwear. The article has a number of contiguous andintegrated foam sub-volumes, designed to achieve a more consistent foamcomponent with fewer, and/or smaller, foam defects. The ridges andstriation bands may be structurally advantageous. The location of thegate vestiges can be beneficially designed to produce flow fronts orboundaries, between and coupling adjacent foam sub-volumes, that arelocated away from key strain areas of the article. In other aspects, thearticle is more environmentally-sustainable, requiring less energy toproduce while still providing good energy return and low density.

At a high level, aspects herein relate to a foamed article, such ascushioning element for an article of footwear, apparel or sportingequipment. The article comprises a foamed component, such as a midsole,having a foamed article volume comprising a plurality of foamsub-volumes, with one injection gate vestige for each foam sub-volume.Each foam sub-volume has a corresponding aspect ratio greater than 2.7.

Other aspects herein relate to a foamed article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componentcomprising a foamed article volume comprising a plurality of foamsub-volumes each having one gate vestige of a plurality of gatevestiges. The component further includes a gate vestige axis extendingbetween a first gate vestige of the plurality of gate vestiges and asecond gate vestige of the plurality of gate vestiges, wherein at leasta third gate vestige of the plurality of gate vestiges is offset fromthe gate vestige axis.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componenthaving a foamed article volume comprising a plurality of foamsub-volumes, the component further comprising one injection gate vestigeat an outward-facing surface of each foam sub-volume, wherein aplurality of ridges on the outward-facing surface extend radiallyoutwardly from an injection gate vestige of at least one of theplurality of foam sub-volumes. In some aspects, the plurality of ridgesform a series of concentric circles.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componentcomprising a profile defined by an outer side wall, the component havinga top surface and a bottom surface, and an outer perimeter edge at theintersection of the outer side wall and the top surface, the top surfacehaving a plurality of striation bands extending inwardly from the outerperimeter edge.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, the component comprising a profiledefined by an outer side wall, the component having a top surface and abottom surface, and an outer perimeter edge at the intersection of theouter side wall and the top surface, wherein at least one of the outerside wall, the top surface and the bottom surface have a substantiallysolid surface skin with a thickness of between 0.3 millimeters and 1.0millimeters.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component having a ratio of energy efficiencyto energy intensity (EE/EI) greater than 1.5. In other aspects, thearticle comprises a physically foamed component having a ratio of energyefficiency to the product of energy intensity and density (EE/EI*ρ)value greater than 7. In other aspects, the article comprises a foamedcomponent having a ratio of energy return to energy intensity (ER/EI)greater than 8,500. In other aspects, the article comprises a foamedcomponent having a ratio of energy return to the product of the energyintensity and the density, ER/(EI*ρ) greater than 45,000.

Also presented herein are manufacturing systems, processes and controllogic for forming foamed thermoplastic polymer articles incorporatingrecycled thermoplastic materials, methods for operating such systems,shoe structure segments fabricated from such articles, and footwearassembled with such segments. In a general sense, the present technologyenables the waste from an injection molding operation (e.g., runnerwaste, flashing, reused foam, etc.) to be reincorporated/integrated intoa subsequently formed midsole such that the net waste from the moldingoperation is greatly reduced and/or eliminated. By way of example, thereis presented a manufacturing process for fabricating a single-piecefoamed midsole of an athletic shoe using scrap and/or waste(collectively “recycled”) thermoplastic, such as a regrind thermoplasticpolyester elastomer (TPE-E) composition. The midsole is a foam componentwith a foam volume, which includes a foam core and an integrally formedskin that encases the foam core.

In an injection molding application, spent scrap and waste thermoplasticmaterial, such as foamed and/or unfoamed TPE-E composition, is groundinto granular form and mixed into a composition containing virginpolymer. The mixture of ground/pelletized recycled material and virginmaterial is heated into a polymer melt composition, which is thenpassed, under pressure, through an injection barrel. While in theinjection barrel, a supercritical fluid (SCF), such as supercriticalnitrogen or supercritical carbon dioxide, may be injected into thepolymer melt composition contained in the barrel, where the SCFdissolves in the melt to form a molten single-phase solution (SPS). Theinjection molding system foams and molds the ground virgin and recycledpolymer using a microcellular molding process in which the SCF isemployed as a physical blowing agent. The SPS may then be flowed intothe mold cavity, at which point system conditions are modulated toactivate transition of the SCF to a gas (e.g., nucleation to a gas) andthe polymer to solidify. This transition of the polymer composition inthe mold cavity may cause the polymer composition to expand (e.g., byfoaming) to fill the mold cavity and, once solidified, retain the shapeof the foam polymer product. The tooling and components of the injectionmolding system, as well as the calibrated parameters for operating themolding system, may be specifically tailored to mold foamed polymerarticles using recycled TPE-E composition. Recombination of regrind andvirgin polymer material may occur, as mentioned above, inside aninjection barrel via a dry blend process; alternatively, regrind andvirgin material recombination may occur on a separate extrusion lineand, once combined, the pre-blended pellets may then be fed into theinjection molder.

Aspects of this disclosure are also directed to manufacturing systemsand processes for fabricating footwear, apparel, and sporting goods fromscrap and waste plastic. In an example, a method is presented formanufacturing foamed polymer articles from recycled TPE-E or TPE-Ecomposition. This representative method includes, in any order and inany combination with any of the above or below disclosed features andoptions: inputting a batch of recycled thermoplastic polyester elastomercomposition; grinding the recyclate batch into a ground recyclatematerial; combining a metered amount of the ground recyclate materialwith ground or pelletized virgin thermoplastic polyester elastomercomposition into a mixed batch, the metered amount being about 20% bymass or less of a total mass of the mixed batch; melting the mixed batchinto a polymer melt composition; adding a physical foaming agent to thepolymer melt composition; injecting the polymer melt composition withthe physical foaming agent into an internal cavity of a mold tool;forming the foamed polymer article by activating the physical foamingagent such that the physical foaming agent causes the polymer meltcomposition to expand and fill the mold tool's internal cavity; andextracting the foamed polymer article from the mold tool.

In another example, a method of manufacturing a foamed polymer articleincludes, in any order and in any combination with the above and/orbelow concepts: grinding a recyclate batch of recycled thermoplasticpolyester elastomer composition into a ground recyclate material;combining a metered amount of the ground recyclate material and a virginpolymer material of virgin thermoplastic polyester elastomer compositioninto a mixed batch; melting the ground recyclate material and the virginpolymer material into a polymer melt composition; adding a physicalfoaming agent to the polymer melt composition; injecting the polymermelt composition with the physical foaming agent into an internal cavityof a mold tool; activating the physical foaming agent such that thephysical foaming agent causes the polymer melt composition to expand andfill the internal cavity of the mold tool to form the foamed polymerarticle; and removing the formed foamed polymer article from the moldtool.

In yet another example, a method of manufacturing a foamed polymerarticle includes, in any order and in any combination with the aboveand/or below concepts: adding a physical foaming agent to a polymer meltcomposition, the polymer melt composition including a blend of arecyclate polymer material and a virgin polymer material, both of virginthermoplastic polyester elastomer compositions, the recyclate polymermaterial being about 20% by mass or less of a total mass of the polymermelt composition; injecting the polymer melt composition with thephysical foaming agent into an internal cavity of a mold tool;activating the physical foaming agent such that the physical foamingagent causes the polymer melt composition to expand and fill theinternal cavity of the mold tool to form the foamed polymer article; andremoving the formed foamed polymer article from the mold tool.

Further aspects of this disclosure are directed to control logic andalgorithms for operating manufacturing systems that fabricate footwear,apparel, and sporting goods from scrap and waste plastic. In an example,a method is presented for operating a manufacturing system to reducewaste during production of a foamed polymer article, such as a solecomponent of a shoe. This representative method includes, in any orderand in any combination with any of the above or below disclosed featuresand options: injecting a mixed thermoplastic composition resin into amold, the mixed thermoplastic composition resin including a mixture ofvirgin thermoplastic composition resin and recycled thermoplasticcomposition resin, and the mold comprising an internal mold cavity thatis fluidly connected to one or more filling portions, such as a sprue,runner, and/or gate; and foaming the mixed thermoplastic compositionresin within the internal mold cavity to form the foamed polymerarticle. In this method, the mass of the recycled thermoplasticcomposition resin within the internal mold cavity is greater than orequal to a mass of the mixed thermoplastic composition resin within thefilling portion of the mold. As such, it may be possible for theentirety of thermoplastic composition within the filling portion of themold to be fully incorporated into subsequently formed soles.

In another example, a method of reducing waste during production of afoamed sole component of a shoe includes, in any order and in anycombination with any of the above or below disclosed features andoptions: injecting a mixed thermoplastic composition resin into a mold,the mixed thermoplastic composition resin comprising a mixture of avirgin thermoplastic composition resin and a recycled thermoplasticcomposition resin, and the mold comprising a sole cavity portion fluidlycoupled to a filling portion; and foaming the mixed thermoplasticcomposition resin within the sole cavity portion to form the foamed solecomponent of the shoe, wherein a mass of the recycled thermoplasticcomposition resin within the sole cavity portion is greater than orequal to a mass of the mixed thermoplastic composition resin within thefilling portion.

Further aspects of the present disclosure are directed to sportinggoods, apparel, footwear, and segments of footwear fabricated from anyof the disclosed processes and materials. For instance, an article offootwear, such as an athletic shoe, includes an upper that receives andattaches to the user's foot. A single-piece or multilayered solestructure, which is attached to a lower portion of the upper, supportsthereon the user's foot. This sole structure includes an outsole thatdefines the ground-engaging portion of the footwear. The sole structureis fabricated with one or more foamed sole components, each of whichincludes a metered amount of a (ground or pelletized) recycledthermoplastic polyester elastomer composition and a (ground orpelletized) virgin thermoplastic polyester elastomer composition. Themetered amount of recyclate TPE-E composition is about 20% by mass orless of a total mass of the mixed batch.

Further aspects of this disclosure are directed to a method ofmanufacturing a foamed polymer article. In this instance, the methodincludes: grinding a recyclate batch of recycled thermoplastic polyesterelastomer composition into a ground recyclate material; combining ametered amount of the ground recyclate material and a virgin polymermaterial of virgin thermoplastic polyester elastomer composition into amixed batch; prior to or after combining, melting the ground recyclatematerial and the virgin polymer material into a polymer meltcomposition; adding a physical foaming agent to the polymer meltcomposition; injecting the polymer melt composition with the physicalfoaming agent into an internal cavity of a mold tool; activating thephysical foaming agent such that the physical foaming agent causes thepolymer melt composition to expand and fill the internal cavity of themold tool to form the foamed polymer article; and removing the formedfoamed polymer article from the mold tool. The formed foamed polymerarticle has: a ratio of energy efficiency to energy intensity that isgreater than about 1.3; a ratio of energy efficiency to the product ofenergy intensity and density that is greater than about 5.9; a ratio ofenergy return to energy intensity that is greater than about 7,225;and/or a ratio of energy return to the product of energy intensity anddensity that is greater than about 38,250.

Additional aspects of this disclosure are directed to method of reducingwaste during production of a foamed polymer article. In this instance,the method includes: injecting a mixed thermoplastic composition resininto a mold, the mixed thermoplastic composition resin comprising amixture of a virgin thermoplastic composition resin and a recycledthermoplastic composition resin; and foaming the mixed thermoplasticcomposition resin within an internal mold cavity of a molding system toform the foamed polymer article, wherein a mass of the recycledthermoplastic composition resin within the mixed thermoplasticcomposition resin is at least about 20% by mass of a total mass of themixed thermoplastic composition resin.

For any of the disclosed systems, methods, articles, and footwear, therecycled TPE-E composition in the recyclate batch includes scrapmaterial or waste material, or both, that was recovered from anun-foamed batch of extruded TPE-E composition and/or a foamed batch ofinjection molded TPE-E composition. As yet a further option, therecycled and virgin TPE-E compositions may be derived from adihydroxy-terminated polydiol material, such as a poly(alkyleneoxide)diol, or a C2-C8 diol material, such as an ethanediol,propanediol, butanediol, pentanediol, or an aromatic dicarboxylic acidmaterial, such as a C5-C16 dicarboxylic acid, or any combinationthereof. In addition, the physical foaming agent may be added byinjecting the physical foaming agent into the polymer melt compositionwhile the polymer melt composition is contained in an injection barrelof an injection molding system. The physical foaming agent may be anSCF, such as supercritical nitrogen and/or supercritical carbon dioxide.

For any of the disclosed systems, methods, articles, and footwear, themixed batch of ground recyclate material and virgin polymer material mayhave a set point temperature of at least about 150° C. or, in someembodiments, ranging from about 190° C. to about 265° C. In this regard,the mixed batch of recyclate and virgin materials may have an averagepeak crystallization temperature of at least about 90° C. or, in someembodiments, ranging from about 135° C. to about 165° C. A resultantfoamed polymer article may have a cell size average, e.g., by volume ofa longest cell dimension, of less than about 0.68 mm or, in someembodiments, about 0.18 mm to about 0.58 mm. Creating the polymer meltcomposition may comprise melting then mixing the recyclate and virginmaterials or melting a mixed batch already containing the recyclate andvirgin materials.

For any of the disclosed systems, methods, articles, and footwear, theresultant foamed polymer article exhibits: a ratio of energy efficiencyto energy intensity that is between about 1.1 and about 1.9; a ratio ofenergy efficiency to the product of energy intensity and density that isbetween about 4.8 and about 9.1; a ratio of energy return to energyintensity that is between about 6,000 and about 11,000; and/or a ratioof energy return to the product of energy intensity and density that isgreater than about 45,000. The recycled and virgin thermoplasticpolyester elastomer compositions may be derived from a block copolymer,a segmented copolymer, a random copolymer, and/or condensationcopolymer, and may have a weight average molecular weight (Mw) of atleast about 30,000 Daltons or, in some embodiments, about 50,000 Daltonsto about 200,000 Daltons.

For any of the disclosed systems, methods, articles, and footwear, theground recyclate material may be processed prior to melting the mixedbatch. This processing may include adding a filler, pigment, and/orprocessing aid to the ground recyclate material (before or afterincorporation into the mixed batch). As yet a further option, adding thephysical foaming agent to the polymer melt composition may includedissolving a supercritical inert fluid into the polymer melt compositionunder pressure to form a single-phase solution. Moreover, activating thephysical foaming agent may include releasing the pressure to expand thesupercritical inert fluid. Receiving the recyclate batch of recycledTPE-E composition may include obtaining, from a sprue, a runner, and/ora gate of an injection molding system, scrap segments of a prior-foamedpolymer article formed from a prior mixed batch of ground recyclatematerial and virgin polymer material.

For any of the disclosed systems, methods, articles, and footwear, aresultant foamed article formed with recycled polymer material may havean energy return measurement that is within a predefined tolerance of anenergy return measurement of a comparable foamed article formed entirelyor almost entirely from virgin polymer material. For example, thepredefined tolerance of a foamed sole component formed with recyclate isabout 75% to about 99% of the energy return measurement of a comparableshoe sole component formed from virgin material. A shoe sole componentmay be considered “comparable” to another sole component if the twoarticles share an equivalent or nearly equivalent common shape, size,and/or method of molding. A percent by mass of the recycledthermoplastic resin within the mixed thermoplastic resin may be lessthan about 30% or, in some embodiments, between about 1% and about 20%.

For any of the disclosed systems, methods, articles, and footwear, thefilling portion of the mold comprises one or more cold runners. In thisinstance, the filling portion may include one or more hot runnersdisposed within one or more runner plates, which may be stacked on andfluidly coupled to one or more mold plates that define therein theinternal mold cavity. Moreover, the filling portion may consist of oneor more channels that direct a flow of mixed thermoplastic resin from anozzle or hot runner of an injection molding apparatus to the internalmold cavity portion of the mold. As yet a further option, the groundrecyclate material may have an irregular shape with a largestmeasurement of about 1-10 mm, and the virgin polymer material has apellet size of about 1-10 mm. A foamed sole component may have a meltingtemperature of at least about 190° C. and an average peakcrystallization temperature of at least about 135° C.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples are described in detail below with reference to the attacheddrawing FIGURES, wherein:

FIG. 1 provides a perspective view of a foam article in the form of acushioning element as a midsole for an article of footwear, inaccordance with aspects described herein;

FIG. 2 provides a top view of the midsole of FIG. 1 , in accordance withaspects described herein;

FIG. 3 provides a bottom view of the midsole of FIG. 1 , in accordancewith aspects described herein;

FIG. 4 provides a medial side view of the midsole of FIG. 1 , inaccordance with aspects described herein;

FIG. 5 provides a lateral side view of the midsole of FIG. 1 , inaccordance with aspects described herein:

FIG. 6 provides a bottom view of an alternative midsole, shown forcomparison of the midsole of FIG. 1 , in accordance with aspectsdescribed herein;

FIG. 7 provides a top image of an aspect of the midsole of FIG. 1 , inaccordance with aspects described herein;

FIG. 8 provides a bottom image of an aspect of the midsole of FIG. 1 ,in accordance with aspects described herein;

FIG. 9 provides an enlarged view of a portion of the midsole of FIG. 7 ,in accordance with aspects described herein;

FIG. 10 provides a view similar to FIG. 9 , in accordance with aspectsdescribed herein;

FIG. 11 provides a further enlarged view of a portion of the midsole ofFIG. 7 , in accordance with aspects described herein;

FIG. 12 provides an enlarged view of a portion of the midsole of FIG. 7, in accordance with aspects described herein;

FIG. 13 provides a view similar to FIG. 12 , in accordance with aspectsdescribed herein;

FIG. 14 provides a view of comparison data regarding the midsole of FIG.1 and the midsole of FIG. 6 , in accordance with aspects describedherein;

FIG. 15 provides a side view of the midsole of FIG. 1 within an articleof footwear, in accordance with aspects described herein;

FIG. 16 provides an image view of a cross-section of the midsole of FIG.1 , showing the surface skin;

FIG. 17 provides a perspective view of one aspect of a three-piece moldused to form the midsole of FIG. 1 ;

FIG. 18 provides a bottom view of the midsole of FIG. 1 , in accordancewith aspects described herein;

FIG. 19 provides a perspective view of one aspect of a three-piece moldused to form the midsole of FIG. 3 ; and

FIG. 20 depicts a flowchart illustrating a representative workflowprocess for manufacturing a foamed polymer article, such as a segment ofan article of footwear, from virgin and recycled thermoplastic polyesterelastomer compositions, which may correspond to memory-storedinstructions executed by a manufacturing system controller,control-logic circuitry, programmable electronic control unit, or otherintegrated circuit (IC) device or a network of IC devices in accord withaspects of the disclosed concepts

DETAILED DESCRIPTION

Aspects herein relate to a foam article, such as a cushioning elementfor an article of footwear, apparel or sporting equipment. In someaspects, the article comprises a physically foamed, injection moldedcomponent, such as a midsole, having a number of beneficial physicalcharacteristics. In some aspects, the physically foamed article is theproduct of foaming a thermoplastic elastomer material using a physicalfoaming agent, or a combination of a physical forming agent and achemical agent. In some aspects, the article comprises a foam component,wherein the foam component has a foam volume, wherein the foam volumeincludes a foam core and an integrally-formed skin that encases the foamcore, wherein both the foam core and the skin comprise a singlethermoplastic elastomer material. Optionally, the foam core can comprisea plurality of integrally formed and connected foam sub-volumes. Thesefoam sub-volumes can form a series of integrally formed and connectedportions of foam in the core, and a series of concentric ridges on theexterior surface of the skin, typically which appear to extend radiallyoutward from an injection gate vestige location. Striation bands mayappear on the exterior surface of the skin, particularly near theperimeter of the foam article. The foam core (including its sub-volumesand portions of foam) can have an open-cell structure or a closed-cellstructure. Additional components, such as solid molded components, canoptionally be combined with the foam component to form an article suchas a sole structure for an article of footwear. The article has a numberof contiguous and integrated foam sub-volumes, designed to achieve amore consistent foam component with fewer, and/or smaller, foam defects.The ridges and striation bands may be structurally advantageous. Thelocation of the gate vestiges can be beneficially designed to produceflow fronts or boundaries, between and coupling adjacent foamsub-volumes, that are located away from key strain areas of the article.In other aspects, the article is more environmentally-sustainable,requiring less energy to produce while still providing good energyreturn and low density.

At a high level, aspects herein relate to a foam article, such as acushioning element for an article of footwear, apparel or sportingequipment. The article comprises a foamed component, such as a midsole,having a foamed article volume comprising a plurality of foamsub-volumes, with one injection gate vestige for each foam sub-volume.Each foam sub-volume has a corresponding aspect ratio greater than 2.7.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componentcomprising a foamed article volume comprising a plurality of foamsub-volumes each having one gate vestige of a plurality of gatevestiges. The component further includes a gate vestige axis extendingbetween a first gate vestige of the plurality of gate vestiges and asecond gate vestige of the plurality of gate vestiges, wherein at leasta third gate vestige of the plurality of gate vestiges is offset fromthe gate vestige axis.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componenthaving a foamed article volume comprising a plurality of foamsub-volumes, the component further comprising one injection gate vestigeat an outward-facing surface of each foam sub-volume, wherein aplurality of ridges on the outward-facing surface extend radiallyoutwardly from an injection gate vestige of at least one of theplurality of foam sub-volumes. In some aspects, the plurality of ridgesform a series of concentric circles.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, such as a midsole, the componentcomprising a profile defined by an outer side wall, the component havinga top surface and a bottom surface, and an outer perimeter edge at theintersection of the outer side wall and the top surface, the top surfacehaving a plurality of striation bands extending inwardly from the outerperimeter edge.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component, the component comprising a profiledefined by an outer side wall, the component having a top surface and abottom surface, and an outer perimeter edge at the intersection of theouter side wall and the top surface, wherein at least one of the outerside wall, top surface and bottom surface have a substantially solidsurface skin surrounding a foam core, with a thickness of between 0.3millimeters and 1.0 millimeters, wherein the skin and foam core comprisea single thermoplastic elastomeric material.

Other aspects herein relate to a foam article, such as a cushioningelement for an article of footwear, apparel or sporting equipment. Thearticle comprises a foamed component having a ratio of energy return toenergy intensity (EE/EI) greater than 1.5. In other aspects, the articlecomprises a foamed component having a ratio of energy return to theproduct of energy intensity and density (EE/EI*ρ) value greater than 7.

The article disclosed herein may be a cushioning element used on anarticle of footwear, an item of apparel, or a piece of sportingequipment. In some aspects, the article of footwear disclosed herein hasa general configuration suitable for various activities, such aswalking, running, jumping, and the like. An article of footwear may takeon various forms in order to provide support to a wearer when performingvarious activities. Exemplary articles of footwear may include athleticfootwear, sandals, dress footwear, boots, loafers, and the like. Theterm “footwear” may be used herein for simplicity, in reference toaspects of the articles of footwear. However, the concepts describedherein may be applied to a variety of other types of footwear.

An exemplary article of the footwear 100 is provided in FIG. 15 , inaccordance with aspects herein. The footwear 100 includes an upper 110and a sole structure 120. For reference purposes, the footwear 100 mayhave a toe end 130, a mid-foot area 132, and a heel end 134. The toe end130 is proximate to portions of the footwear 100 that correspond withthe toes and the joints connecting the metatarsals with the phalanges ofa foot of a wearer, in the as-worn position. For reference purposes, theas-worn position refers to a position of the foot of the wearer inrelation to the footwear when the wearer dons the footwear 100. Themid-foot area 132 generally includes portions of the footwear 100corresponding with middle portions of the foot including, at least, thecuboid, navicular, medial cuneiform, intermediate cuneiform, and lateralcuneiform bones of the foot of the wearer, in the as-worn position. Theheel end 134 is opposite the toe end 130 and is proximate to portions ofthe footwear 100 that correspond with the heel of the foot, includingthe calcaneus bone of the foot of the wearer, in the as-worn position.The toe end 130, the mid-foot area 132, and the heel end 134 are notintended to demarcate precise areas of the footwear 100, but rather areintended to represent general ends and areas of the footwear 100 to aidin the following discussion.

The upper 110 defines a cavity within the footwear 100 for receiving andsecuring a foot relative to the sole structure 120. The cavity may beshaped to accommodate the foot and extends along a lateral side of thefoot, along a medial side of the foot, over the foot, around a heel ofthe foot, and may extend under the foot. Access to the cavity may beprovided by an ankle opening 112 located near atop portion of the upper110, in the as-worn position. In some aspects, the upper 110 may includea strobel. Various portions of the upper 110 may be made from aplurality of elements, including textiles, polymer sheet layers, foamlayers, leather, synthetic leather, and the like, that may be joinedtogether or seamlessly formed (e.g., woven or knit) to provide thecavity within the footwear 100.

The sole structure 120 may have, among other things, in some aspects, acushioning element, such as a midsole 122, and an outsole 124. The solestructure 120 may attenuate ground reaction forces and absorb energy asthe footwear 100 contacts the ground. The midsole 122, among otherthings, may act as a cushioning element. Additionally, aspects of thesole structure 120 may provide stability to at least the foot of thewearer during various activities, such as rapid lateral directionchanges, lunges, and jumping.

In some aspects, the article of the footwear 100 can also include one ormore fluid-filled chambers, such as airbags/airsoles, disposed (i)between the upper 110 and the midsole 122, (ii) within a pocket in themidsole 122, and/or (iii) between the midsole 122 and the outsole 124.The fluid-filled chamber may be formed using any suitable manufacturingtechnique, such as blow molding, thermoforming and post-inflation, andthe like. The fluid-filled bladder can be produced from single-layerfilms or multiple-layer films, such as multiple-layer barrier films.Barrier films, such as those disclosed in Bon et al., U.S. Pat. No.6,599,597, can include alternating layers of structure materials (e.g.,thermoplastic polyurethane) and gas-barrier materials (e.g.,ethylenevinyl alcohol). Fluid-filled chambers with such barrier filmsare beneficial for good flexibility for use as footwear cushioningelements as well as retaining pressurized gases for extended durations(e.g., pressurized nitrogen). Alternatively, the fluid-filled chambercan retain gases at ambient pressure (e.g., atmospheric pressure). Insome aspects, the fluid-filled chamber can also include one or moretensile elements, such as those disclosed in Chao et al., U.S. Pat. No.8,869,430 and Hazenberg et al., U.S. Pat. No. 9,021,720. Each tensileelement may include a series of tensile strands (e.g., polyamide and/orthermoplastic polyurethane strands) extending between the major filmsurfaces of the fluid-filled chamber.

In further aspects, the article of the footwear 100 can also include oneor more midsole plates disposed (i) between the upper 110 and themidsole 122, (ii) between multiple stacks of the midsole 122, and/or(iii) between the midsole 122 and the outsole 124. Examples of suitableplates for use in the article of footwear include those disclosed inDupre et al., U.S. Pat. No. 10,448,704 and Connell et al., U.S.publication No. 2018/0213886. Each plate may be formed from a non-foamedpolymer material or, alternatively, from a composite of one or morepolymeric materials and entrained fibers (e.g., carbon fibers). As such,each plate can exhibit relatively rigid, yet flexible properties todistribute forces associated with the use of the article of the footwear100 when the article of the footwear 100 strikes a ground surface.

FIGS. 1-5 provide views of one aspect of the foam article, shown as athe midsole 122, that may serve a variety of purposes that includesupporting and controlling foot motions and as a cushioning element(attenuating impact forces that are generated when a foot contacts theground). For reference purposes, the midsole 122 may have a foamedcomponent 136, having a profile 138 defined by an outer side wall 140.The component 136 further has a top surface 142 and a bottom surface 144spaced from the top surface 142. In some aspects, the foam component 136has a foam core and an integrally formed surface skin, wherein both thefoam core and the surface skin comprise a single thermoplasticelastomeric material. In some aspects, the surface skin forms the topsurface 142, the bottom surface 144 and the side wall 140. The bottomsurface 144 of the midsole 122 may be joined to the outsole 124, such asby an adhesive, or the midsole 122 may be over-molded with the outsole124. The upper 110 may be joined to the top surface 142, such as by anadhesive. An outer perimeter edge 146 extends around the periphery ofthe midsole 122 at the intersection of the outer side wall 140 and thetop surface 142. Like the footwear 110, the midsole 122 has acorresponding toe area 148, a heel area 150 and a mid-foot area 152 thatextends generally between the toe area 148 and the heel area 150. Thetoe area 148, the mid-foot area 152 and the heel area 150 are notintended to demarcate precise areas of the midsole 122 but are intendedto represent respective areas of the footwear 100 that provide a frameof reference. The perimeter edge 146 may, in some aspects, transitionfrom a narrower edge 146 a near the toe area 148 to a wider edge 146 bnear the heel area 150. The bottom surface 144 extends between the outerside walls 140 on the bottom of the midsole 122 and extends from theheel area 150 to the toe area 148. As best seen in FIGS. 1 and 2 , thetop surface 142 extends between the outer side walls 140 on the top ofthe midsole 122 and also extends from the heel area 150 to the toe area148. In some aspects the top surface 142 is formed in a concave or cupshape by the mold, and in some aspects the area adjacent the perimeteredge 146 has a smaller radius of curvature as the top surface 142transitions to the perimeter edge 146.

The midsole 122 is produced in a mold 123 (such as that shown in FIG. 17), where a mixture of a molten thermoplastic elastomer and a foamingagent are injected into the mold cavity 127 through a number of gateopenings 125. In one aspect, the midsole 122 is formed in a mold havingsix gates, evidenced by six remaining gate vestiges 160 protrudingslightly from the bottom surface 144 of the midsole 122. In someaspects, the gate vestiges 160 do not protrude from the bottom surface144 of the midsole 122, but are evidenced by other factors discussedbelow. The gate vestiges 160 are labeled 160 a-160 f in FIG. 3 ,extending from the toe area 148 to the heel area 150. Each gate vestige160 has a corresponding foam sub-volume 164 (correspondingly labeled 164a-164 f in FIG. 3 ) representing a sub-volume of the entire articlevolume of the midsole 122 substantially filled from the compositioninjected through a corresponding gate at a gate vestige 160 location. Itshould be understood that foam from adjacent gate vestiges 160 will flowtogether to fill the article volume to form a foam-filled the midsole122.

Single Gate

In other aspects, the midsole 122 is produced in a mold 123 (such asthat shown in FIG. 19 ), where a mixture of a molten thermoplasticelastomer and a foaming agent are injected into the mold cavity 127through a single gate opening 125 in each mold cavity. In this aspect,the midsole 122 is formed in a mold having a single gate opening 125,evidenced by a single remaining gate vestige 160 g (as shown in FIG. 18) protruding slightly from the bottom surface 144 of the midsole 122. Insome aspects, the gate vestige 160 g does not protrude from the bottomsurface 144 of the midsole 122, but is evidenced by other factorsdiscussed below. In this aspect, the single gate vestige 160 g has acorresponding foam volume 164 g (the entire foam volume being filledthrough the single gate 125). In some aspects, the single gate opening125 is located along a central axis 172, and slightly forward of theheel area. Other locations of a single gate opening 125 could also beused, in some aspects.

Striation Bands

As best seen in FIGS. 2, 7 and 9-13 , the physical foaming, along withthe mold design and the process conditions (such as pressure, time andtemperature) may be coordinated to produce striation bands 170 in thetop surface 142 adjacent at least some areas of the perimeter edge 146in at least some of the foam sub-volumes 164. In one aspect, thestriation bands 170 extend substantially radially from the perimeteredge 146 toward at least one gate vestige 160. In one aspect, thestriation bands 170 extend at least 5 millimeters (mm) inwardly from theperimeter edge 146, or at least 10 mm inwardly from the perimeter edge146, or at least 15 millimeters inwardly from the perimeter edge 146.The striation bands 170, in one aspect, generally extend around theentire periphery of the toe area 148 of the midsole 122. In anotheraspect, the striation bands 170 extend at least in the center of theheel area 150, near a gate vestige axis 172 of the midsole 122. In oneaspect, the striation bands 170 extend from the perimeter edge 146 in atleast one section of the mid-foot area 152. In one aspect, the striationbands 170 are formed by the shear applied to the foamed polymer as itexpands at increasing velocity as the mold cavity narrows or getsthinner in this region. This thinner region is formed as the top surface142 meets with the side wall 140, generally in areas that form a thinnerwall, as opposed to a gradually rounded boundary. This thinner area nearthe perimeter edge 146 is used to embed the upper 110 and provide asmooth transition between the midsole 122 and the upper 110 when themidsole 122 is within the footwear 100. These thinner-walled areas aremore prone to tearing, particularly in the toe area 148. Additionally,these thinner-walled areas can extend relatively higher above theremainder of the top surface 142, and as such are potentially morevulnerable to tearing. The striation bands 170 are portions of thefoamed component where polymer chains present in this portion have ahigher degree of orientation relative to portions of the midsole 122without the striation bands 170. Without intending to be bound by anytheory, it is believed that the striation bands 170 may increase thestrength and tear resistance of the midsole 122 in thinner wall areas,such as those areas adjacent the perimeter edge 146. The striation bands170 may also form a slightly textured surface, increasing the surfacearea of the top surface 142 near the perimeter edge 146, allowing anincrease in bond strength of any adhesive used to couple the midsole 122to a corresponding part. In one aspect, the striation bands 170 mayextend about 5 millimeters, or about 10 millimeters, or about 15millimeters or about 20 millimeters from the perimeter edge 146.

Gate Location and Flow

The number and positioning of the gates can impact the performancecharacteristics of the resulting foam article, such as the midsole 122.As best seen in FIG. 3 (and the photograph shown as FIG. 8 ), thephysical foaming, along with the mold design and the process conditions(such as pressure, time and temperature) may be coordinated to produce aseries of approximate concentric ridges 174 that generally radiateoutwardly from each gate vestige 160 as best seen from the bottomsurface 144, in either the multiple gate aspects shown in FIG. 3 or thesingle gate aspect shown in FIG. 18 . In one aspect, the concentricridges 174 are formed as the melt composition expands into the physicalfoam radiating outwardly from the respective gate vestige 160. In someaspects, it is believed the concentric ridges 174 can act to distributecompression forces in a more uniform way, in multiple directions, as themidsole 122 is used as a cushioning element in an article of thefootwear 100. In some aspects, the concentric ridges 174 radiateoutwardly at least 10 mm from the respective gate vestige 160. In someaspects, the concentric ridges 174 radiate outwardly at least 20 mm fromthe respective gate vestige 160. In some aspects, the concentric ridges174 radiate outwardly at least 30 mm from the respective gate vestige160. In some aspects, the concentric ridges 174 radiate furtheroutwardly in the toe area 148 of the midsole 122 than in the mid-footarea 152 and/or the heel area 150 of the midsole 122. In some aspects,the shape formed by the ridges 174 is more ovular than circular. In someaspects, the shorter axis of the ovular shape formed by the ridges 174is in-line with the gate vestige axis 172 and the longer axis of theovular shape formed by the ridges 174 is orthogonal to the gate vestigeaxis 172.

As shown in FIG. 3 , an intersection axis 176 can be defined at the apexof curvature of the outer side wall 140 on both the medial side and thelateral side of the midsole 122, between the toe area 148 and themid-foot area 152, generally at a location known as the ball width. Asthe midsole 122 is formed, the thermoplastic elastomer compositioninjected into a mold cavity at the gate vestige locations 160 expands tofill a respective foam sub-volume 164. A foam front, or flow boundary isrepresented by the line 178. The foam flow boundary 178 schematicallyrepresents the front of the foamed thermoplastic elastomer compositionas it forms a partition boundary between foam sub-volume 164 a and foamsub-volume 164 b. It can be seen that the foam flow boundary 178intersects the intersection axis 176 in two locations. The location ofthe foam flow boundary 178 is preferably in an area that does notcoincide with an area of maximum peak strain when the midsole 122 isused in an article of footwear and when the user is walking and/orrunning. The location of the foam flow boundary is designed andpositioned by positioning and locating the gates (and gate vestiges 160a and 160 b), as well as the properties of the foamed thermoplasticelastomer composition and the process conditions.

Aspect Ratio

In injection molding, the parameter known as the aspect ratio (AR) maybe calculated for each part, and specifically for each injection gatefor the part (such as the midsole 122). For three-dimensional shapes,the aspect ratio is defined as the ratio of the maximum dimension of theshape to the minimum dimension of the shape. For regular shapes, (suchas spheres, cubes, rectangles, cylinders, etc.) aspect ratio is definedby length/width, with distances measured from the center of the shape.For a perfect sphere, the AR is 1. For a cube, the AR is half thedimension of a side, divided by the distance from the center of the cubeto a corner. For irregular shapes frequently encountered in injectionmolding, such as for the midsole 122, no single dimension accuratelyrepresents the shape. For irregular shapes, the aspect ratio can bedefined as the ratio of the maximum distance from the center of mass ofthe equivalent solid of the shape to the surface of the shape (L_(max))relative to the minimum distance from the same point to the surface(L_(min)). For foam volumes with multiple gates, such as the midsole 122with the sub-volumes 164, the volume allocated to each gate (orindividual foam sub-volume 164) should be considered as having its owncharacteristic aspect ratio based on the fractional volume of theoverall cavity of the mold for the midsole 122. The boundaries of eachfoam sub-volume 164 are determined along with the volumes and centers ofmass associated with each gate and foam sub-volume 164. These parameterscan be calculated using CAD mold simulation software, as is known tothose of skill in the art. From the volume and centers of mass, theaspect ratio is calculated for each foam sub-volume 164.

Higher aspect ratio (AR) cavities are believed to create more consistentfoam structures compared to low aspect ratio cavities. For example, themidsole 122 of FIGS. 1-5 discussed above, molded with six gatesevidenced by six injection gate vestiges 160 may be compared with a themidsole 122A, shown in FIG. 6 , molded with four gates evidenced by fourinjection gate vestiges 160A. FIG. 14 , shows a comparison in foammicrostructures between the midsole 122 and the midsole 122A having thesame overall shape but different gate configurations. The midsole 122and the midsole 122A are composed of the same material, have equivalentdensity, and were injected using the same conditions (such as time,pressure and temperature). Images A-F in FIG. 14 highlight localdifferences in foam structure between the midsole 122 (molded with sixgates) and the midsole 122A (molded with four gates). Images A, B and Care from the heel area 150, the mid-foot area 152 and the toe area 148,respectively, of the midsole 122A. Similarly, images D, E and F are fromthe heel area 150, the mid-foot area 152 and the toe area 148,respectively, of the midsole 122. Image pairs A-D, B-E, and C-F weretaken from the same zones on the 4 gate the midsole 122A (also labeled Gin FIG. 14 ) and 6 gate the midsole 122 (also labeled H in FIG. 14 ),respectively. The area of the midsole 122 and the midsole 122A resultingin images A-F are indicated in FIG. 14 with a corresponding letter inthe images labeled G and H. Image I in FIG. 14 shows a representativedefect free foam microstructure characteristic of both the midsole 122and the midsole 122A. A defect in the foam microstructure can be definedas any area with a single dimension greater than 1 mm. Put another way,any area in a micrograph where a 1 mm line can be drawn without crossinga foam strut (or wall) is defined as a defect. The regions correspondingto defects are indicated with black dots in images A-F. A representativedefect 180 is shown in FIG. 14 , but it should be understood that eachblack dot in images A-F represents a defect, and that not all defects180 are labeled in the images for the sake of clarity. The area of eachdefect is calculated by fitting a polygon consisting of an arbitrarynumber of edges to each area of interest. The sum of all the defectareas is shown under A in table J of FIG. 14 . The table labeled J inFIG. 14 compares the aspect ratio (AR)(calculated as described above),the size of the largest defect 180 (shown under S in table J) andoverall defect area (A) between the image pairs in similar areas of themidsole 122 and the midsole 122A. Notably, there are marked differencesin the largest defect size S and overall defect area A when the aspectratio is different. The images corresponding to higher aspect ratio foamsub-volumes 164 have smaller defects 180 and lower overall defect areacompared to the lower aspect ratio foam volumes. In areas absent ofdefects, the foam cells themselves have similar structure (I) regardlessof gate configuration.

When comparing the midsole 122 with the midsole 122A, the number ofinjection gate vestiges 160 (corresponding to the number of injectiongates) is chosen such that the AR for any foam sub-volume 164 is greaterthan a threshold. In one aspect, the AR is greater than 2.7, or greaterthan 3, or greater than 3.5. To achieve these aspect ratios, themid-foot area 152 of the midsole 122 has two injection gate vestiges 160c and 160 d generally in line with the gate vestige axis 172.Additionally, the heel area 150 has two injection gate vestiges 160 eand 160 f that are offset from the gate vestige axis 172. In one aspect,the gate vestige 160 e and the gate vestige 160 f form a line that isorthogonal to the gate vestige axis 172. In some aspects, a gate vestige160 (and a corresponding injection gate in the mold) is added for themidsole 122 when the aspect ratio is below about 3.5, or below about 3or below about 2.7. Generally, the goal in design is to add and positionnew gates (and resulting gate vestiges 160) at locations resulting in anincreased AR of the new foam sub-volumes 164. As new gates (andresulting gate vestiges 160) are added, the shot size of the meltcomposition (thermoplastic elastomer composition and foaming agent) isreduced to account for the smaller sub-volume.

As further described herein, for both open-cell and closed-cellstructures, the proportion of cells in the thermoplastic elastomer foamof the midsole 122 having a cell diameter of about 50 micrometers toabout 1000 micrometers is preferably not less than 40 percent relativeto all the cells, or not less than 50 percent or not less than 60percent relative to all the cells. If the proportion of cells is lessthan 40 percent, the cell structure will tend to be nonuniform and/orhave a coarse cell structure. As used herein, a “coarse cell structure”refers to a foam structure in which the average cell diameter is greaterthan 1 millimeter, and/or for greater than 20 percent of the cells, a 1millimeter line drawn across the largest dimension of the cell, will notcross a cell wall or a strut (i.e., an open cell wall or portionthereof).

The number of open cells and/or closed cells and cell diameter of thecells of the foam can be determined visually, for example by capturingan image of a cut surface with a camera, CT scan or digital microscopeand as seen in representative images A-F in FIG. 14 , determining thenumber of cells, number of open cells and/or number of closed cells, anddetermining an area of a cell, and converting it to the equivalentcircle diameter.

The bubble or cell size within any foam sub-volume 164 of the midsole122 has an average cell size gradient with the greater cell sizes in themiddle of a respective foam sub-volume 164 and smaller cell sizes as thethermoplastic elastomer foam of the midsole 122 nears the top surface142 and the bottom surface 144. As best seen in FIG. 16 , thethermoplastic elastomer foam, the process conditions, and the design ofthe midsole 122 create a substantially non-porous, non-foamed(substantially solid) polymeric material surface skin 156 on at leastsome of the outward facing surfaces of the midsole 122 (such as the topsurface 142, the bottom surface 144 and the outer side wall 140). In oneaspect, all of the outward facing surfaces of the midsole 122 (such asthe top surface 142, the bottom surface 144 and the outer side wall 140)have a surface skin 156. The surface skin 156 is free from any opencells, and allows the midsole 122 to be used in manufacturing withoutfurther processing. The surface skin 156 is of the same material as theremainder of the midsole 122 and is integrally formed therewith, but thematerial is unfoamed, or without a cellular structure (or is a collapsedcell structure) that is substantially solid. In some aspects, thesurface skin has a thickness of about 0.5 millimeters to about 0.9millimeters, or about 0.6 millimeters to about 0.8 millimeters, or fromabout 0.3 millimeters to about 1 millimeters.

In some aspects, the average cell size of the foam decreases from anaverage cell size of about one millimeter near the center of any foamsub-volume 164 to an average cell size of less than 0.5 millimeters nearthe surface skin 156. The cell sizes range from about 1-2 millimeters,or about 0.5-3 millimeters, or about 0.25-3 millimeters.

Foamed Thermoplastic Elastomer Composition

The present disclosure is directed to an article which includes a foamcomponent comprising a foamed thermoplastic elastomer composition. Thefoam component includes a foamed thermoplastic elastomer compositionhaving a multicellular foam structure, for example, a multicellularopen-cell or closed-cell foam structure. The foam component can includethe foamed thermoplastic elastomer composition having a multicellularopen-cell structure. The article can be a component, such as acushioning element, for an article of footwear, an article of apparel,or an article of sporting equipment. In one example, the article is acushioning element for an article of footwear, such as midsole or amidsole component.

It has been found that thermoplastic elastomer compositions (i.e.,polymeric compositions comprising one or more thermoplastic elastomer),including thermoplastic polyester compositions (i.e., polymericcompositions comprising one or more thermoplastic polyester elastomer)can be used to form multicellular foams having advantageous propertiesfor use in consumer articles such as cushioning elements. As usedherein, and discussed further below, the term polyester can refer topolyester homopolymers and/or copolyester polymers having at least onepolyester monomeric segment. When foamed as described herein, thesemulticellular foams retain thermoplastic properties, making it possibleto readily recycle and reuse the thermoplastic elastomer composition ofthe foam. For example, once foamed, the thermoplastic elastomercomposition can be ground, melted to eliminate its foam structure andfoamed again, or can be ground, melted to eliminate its foam structureand molded into an article having a non-foamed structure (i.e., a solidarticle).

The foam components disclosed herein are formed by foaming thethermoplastic elastomer composition into a multicellular foam having anopen-cell or a closed-cell foam structure. The thermoplastic elastomercomposition can be a thermoplastic polyester composition comprising oneor more thermoplastic polyester elastomer. Examples of thermoplasticpolyesters include polymers which have one or more carboxylic acidfunctional group present in the polymeric backbone, on one or more sidechains, or both in the polymeric backbone and on one or more sidechains. The one or more carboxylic acid functional group ofthermoplastic polyester can include a free carboxylic acid, a salt of acarboxylic acid, or an anhydride of a carboxylic acid. The carboxylicacid functional group of thermoplastic polyester can be an acrylic acidfunctional group or a methacrylic acid functional group.

The thermoplastic elastomer composition can include at least 90 weightpercent, or at least 95 weight percent, or at least 99 weight percent,of a polymeric component comprising all of the polymeric materialspresent in the thermoplastic elastomer composition, based on a totalweight of the thermoplastic elastomer composition. In some aspects, thethermoplastic polyester composition includes at least 90 weight percent,or at least 95 weight percent, or at least 99 weight percent of apolymeric component comprising all thermoplastic polyesters present inthe thermoplastic polyester composition based on the total weight ofthermoplastic polyester composition, e.g., one or more thermoplasticpolyester elastomers as disclosed herein, based on the total weight ofthermoplastic polyester composition. In some such aspects, thethermoplastic elastomer composition (or thermoplastic polyestercomposition) is substantially free of a non-polymeric component. Thenon-polymeric component may include all non-polymeric materials presentin the thermoplastic elastomer composition or thermoplastic polyestercomposition, or may include particular types of non-polymeric materialspresent in the thermoplastic elastomer composition or the thermoplasticpolyester composition. Examples of non-polymeric components can includeone or more of nucleating agents, non-polymeric fillers, chemicalfoaming agents, coloring agents such as pigments and/or dyes, processingaids, and the like. In some examples, the thermoplastic elastomercomposition (or thermoplastic polyester composition) is substantiallyfree of nucleating agents, or is substantially free of non-polymericfillers, or is substantially free of coloring agents, or issubstantially free of both non-polymeric nucleating agents andnon-polymeric fillers, or is substantially free of non-polymericnucleating agents, non-polymeric fillers, and coloring agents. Usingthermoplastic polyester compositions with low levels of non-polymericingredients such as nucleating agents, fillers and coloring agentsincreases the potential for re-using and recycling these compositions,as these compositions can be used in uses where the presence of one ormore of these ingredients is not desired or would require dilution byadding in virgin polymers. Further, the lack of high levels of fillersor coloring agents in the polymeric compositions can reduce the specificgravity of the foams as compared to compositions with high levels ofnon-polymeric ingredients, and can allow the formation of foams havingopen-cell foam structures, which can further reduce the specific gravityof the foams.

The article or foam component comprising the thermoplastic elastomerfoam can be formed by injection molding and foaming the thermoplasticelastomer polymeric material as described herein to form an article orfoam component which can be directly incorporated into an article offootwear, apparel, or sporting equipment without any additionalprocessing, i.e., the dimensions and/or external surfaces of theinjection molded foam may not require any modification. When physicalfoaming agents are used, the injection molded foams formed from thethermoplastic elastomer compositions, including thermoplastic polyestercompositions, have been found to be very dimensionally stable in thatthe foam articles or components shrink very little after being releasedfrom the mold and do not require any additional processing in order tostabilize the foam, allowing “one-to-one” injection molding processes tobe used, in which the resulting molded foam article or component isessentially the same size as the mold used in the injection moldingprocess. Alternatively, the injection molded foam article or componentcan be further processed such as, for example, by stabilizing the foamusing an annealing process, by compression molding the injection moldedfoam article or component into a finished foam, and/or by applying acoating or decorative element to the injection molded foam article orcomponent.

Characteristics of Thermoplastic Elastomer Foam Components

A disclosed thermoplastic elastomer foam (i.e., a foam formed byexpanding a thermoplastic elastomer composition as disclosed herein),including thermoplastic polyester foams, can exhibit various beneficialproperties. For example, the thermoplastic elastomer foam can exhibit abeneficial split tear, for example a high split tear value for a solecomponent in an article of footwear. In some aspects, the thermoplasticelastomer foam can have a split tear value of greater than about 1.5kilogram/centimeter (kg/cm), or greater than about 2.0 kg/cm, or greaterthan about 2.5 kg/cm, when determined using the Split Tear Test Methoddescribed herein. In some aspects, the thermoplastic elastomer foam canhave a split tear value of 1.0 kg/cm to 4.5 kg/cm, or 1.0 kg/cm to 4.0kg/cm, or 1.5 kg/cm to 4.0 kg/cm, or 2.0 kg/cm to 3.5 kg/cm, or 2.5kg/cm to 3.5 kg/cm, when determined using the Split Tear Test methoddescribed herein. The thermoplastic elastomer foam can have a split tearvalue of 0.8 kg/cm to 4.0 kg/cm, or 0.9 kg/cm to 3.0 kg/cm, or 1.0 to3.0 kg/cm, or of 1.0 kg/cm to 2.5 kg/cm, or 1 kg/cm to 2 kg/cm. In someaspects, the thermoplastic elastomer foam is injection molded, and has asplit tear value of 0.7 kg/cm to 2.5 kg/cm, or 0.8 kg/cm to 2.0 kg/cm,or 0.9 to 1.5 kg/cm, or 1.0 kg/cm to 2.5 kg/cm, or of 1.0 kg/cm to 2.2kg/cm. The thermoplastic elastomer foam can have an open-cell foamstructure. The thermoplastic elastomer foam can be the product ofphysically foaming a thermoplastic elastomer composition as disclosedherein, i.e., a foam formed using a physical foaming agent (i.e., aphysical blowing agent). As used herein, a thermoplastic elastomer foamis understood to refer to a foamed material which has thermoplastic andelastomeric properties. The thermoplastic elastomer foam can be thefoamed product of foaming a thermoplastic elastomer compositioncomprising less than 10 weight percent, or less than 5 weight percent,or less than 1 weight percent of non-polymeric ingredients based on atotal weight of the thermoplastic elastomer composition. In someaspects, the thermoplastic elastomer foam is injection molded (i.e., isnot exposed to a separate compression molding step after being formed byinjection molding and removed from the injection mold). In otheraspects, the thermoplastic elastomer foam is injection molded andsubsequently compression molded in a separate compression mold havingdifferent dimensions than the mold used in the injection molding step.

The density or specific gravity of a disclosed thermoplastic elastomerfoam, including a thermoplastic polyester foam, is also an importantphysical property to consider when using a foam for an article ofapparel, footwear or athletic equipment. As discussed above, thethermoplastic elastomer foam of the present disclosure exhibits a lowdensity or specific gravity, which beneficially reduces the weight ofmidsoles or other components containing the thermoplastic elastomerfoam.

The thermoplastic elastomer foams of the present disclosure, includingthermoplastic polyester foams, can have a specific gravity of from 0.02to 0.22, or 0.03 to 0.12, or 0.04 to 0.10, or 0.11 to 0.12, or 0.10 to0.12, or 0.15 to 0.20, or 0.15 to 0.30, when determined using theSpecific Gravity Test Method described herein. In some aspects, thethermoplastic elastomer foams can have a specific gravity of from 0.15to 0.22, such as from 0.17 to 0.22 or from 0.18 to 0.21, when determinedusing the Specific Gravity Test Method described herein. Alternativelyor in addition, the thermoplastic elastomer foam can have a specificgravity of from 0.01 to 0.10, or 0.02 to 0.08, or 0.03 to 0.06, or 0.08to 0.15, or 0.10 to 0.12, when determined using the Specific GravityTest Method described herein. For example, the specific gravity of thethermoplastic elastomer foam can be from 0.15 to 0.2, or 0.10 to 0.12.The thermoplastic elastomer foam can be injection molded, or can beinjection molded and subsequently compression molded. In some aspects,the thermoplastic elastomer foam has a specific gravity of about 0.7 orless, or 0.5 or less, or 0.4 or less, or 0.3 or less, when determinedusing the Specific Gravity Test Method described herein. In someaspects, the thermoplastic elastomer foam, including the thermoplasticelastomer foam present in midsoles and midsole components, can have aspecific gravity of 0.05 to 0.25, or 0.05 to 0.2, or 0.05 to 0.15, or0.08 to 0.15, or 0.08 to 0.20, or 0.08 to 0.25, or 0.1 to 0.15, whendetermined using the Specific Gravity Test Method described herein. Insome aspects the thermoplastic elastomer foam has a specific gravity ofabout 0.15 to about 0.3, or about 0.2 to about 0.35, or about 0.15 toabout 0.25, when determined using the Specific Gravity Test Methoddescribed herein. The thermoplastic elastomer foam article or articlecomponent can be formed by injection molding without a subsequentcompression molding step. The thermoplastic elastomer foam can have anopen-cell foam structure. The thermoplastic elastomer foam can be thefoamed product of foaming a thermoplastic elastomer compositioncomprising less than 10 weight percent, or less than 5 weight percent,or less than 1 weight percent of non-polymeric ingredients based on atotal weight of the thermoplastic elastomer composition.

The thermoplastic elastomer foams of the present disclosure, includingthermoplastic polyester foams, can have a density of from 0.02 grams percubic centimeter (g/cc) to 0.22 g/cc, or 0.03 g/cc to 0.12 g/cc, or 0.04g/cc to 0.10 g/cc, or 0.11 g/cc to 0.12 g/cc, or 0.10 g/cc to 0.12 g/cc,or 0.15 g/cc to 0.2 g/cc, or 0.15 g/cc to 0.30 g/cc, when determinedusing the Density Test Method described herein. In some aspects, thethermoplastic elastomer foams can have a density of from 0.15 g/cc to0.22 g/cc, such as from 0.17 g/cc to 0.22 g/cc, or from 0.18 g/cc to0.21 g/cc, when determined using the Density Test Method describedherein. Alternatively or in addition, the thermoplastic elastomer foamcan have a density of from 0.01 g/cc to 0.10 g/cc, or 0.02 g/cc to 0.08g/cc, or 0.03 g/cc to 0.06 g/cc, or 0.08 g/cc to 0.15 g/cc, or 0.10 g/ccto 0.12 g/cc, when determined using the Density Test Method describedherein. For example, the density of the thermoplastic elastomer foam canbe from 0.15 g/cc to 0.2 g/cc, or 0.10 g/cc to 0.12 g/cc. Thethermoplastic elastomer foam can be injection molded, or can beinjection molded and subsequently compression molded. In some aspects,the thermoplastic elastomer foam has a density of about 0.7 g/cc orless, or 0.5 g/cc or less, or 0.4 g/cc or less, or 0.3 g/cc or less, or0.2 g/cc or less, when determined using the Density Test Methoddescribed herein. In some aspects, the thermoplastic elastomer foam,including the thermoplastic elastomer foam present in midsoles andmidsole components, can have a density of 0.05 g/cc to 0.25 g/cc, or0.05 g/cc to 0.2 g/cc, or 0.05 g/cc to 0.15 g/cc, or 0.08 g/cc to 0.15g/cc, or 0.08 g/cc to 0.20 g/cc, or 0.08 g/cc to 0.25 g/cc, or 0.10 g/ccto 0.15 g/cc, when determined using the Density Test Method describedherein. In some aspects the thermoplastic elastomer foam has a densityof about 0.15 g/cc to about 0.30 g/cc, or about 0.20 g/cc to about 0.35g/cc, or about 0.15 g/cc to about 0.25 g/cc, when determined using theDensity Test Method described herein. The thermoplastic elastomer foamarticle or article component can be formed by injection molding withouta subsequent compression molding step. The thermoplastic elastomer foamcan have an open-cell foam structure. The thermoplastic elastomer foamcan be the foamed product of foaming a thermoplastic elastomercomposition comprising less than 10 weight percent, or less than 5weight percent, or less than 1 weight percent of non-polymericingredients based on a total weight of the thermoplastic elastomercomposition.

The thermoplastic elastomer foam portion of the article or component ofan article, including thermoplastic polyester foam portion, can have astiffness of about 200 kPa to about 1000 kPa, or about 300 to about 900kPa, or about 400 to about 800 kPa, or about 500 to about 700 kPa, whendetermined using the Cyclic Compression Test for a Sample with a 45millimeter diameter cylindrical sample. The thermoplastic elastomer foamportion of the article or component of an article can have a stiffnessof about 100 N/mm to about 400 N/mm, or about 150 N/mm to about 350N/mm, or about 200 N/mm to about 300 N/mm, or about 225 N/mm to about275 N/mm, when determined using the Cyclic Compression Test for a FootForm with the foot form sample. The thermoplastic elastomer foam articleor article component can be formed by injection molding without asubsequent compression molding step. The thermoplastic elastomer foamcan have an open-cell foam structure. The thermoplastic elastomer foamcan be the foamed product of foaming a thermoplastic elastomercomposition comprising less than 10 weight percent, or less than 5weight percent, or less than 1 weight percent of non-polymericingredients based on a total weight of the thermoplastic elastomercomposition.

The thermoplastic elastomer foam portion of the article or component ofan article, including a thermoplastic polyester portion, can have anAsker C durometer hardness of from about 30 to about 50, or from about35 to about 45, or from about 30 to about 45, or from about 30 to about40, when determined using the Durometer Hardness Test described herein.The thermoplastic elastomer foam article or article component can beformed by injection molding without a subsequent compression moldingstep. The thermoplastic elastomer foam can have an open-cell foamstructure. The thermoplastic elastomer foam can be the foamed product offoaming a thermoplastic elastomer composition comprising less than 10weight percent, or less than 5 weight percent, or less than 1 weightpercent of non-polymeric ingredients based on a total weight of thethermoplastic elastomer composition.

The energy input of a foam is the integral of the force displacementcurve during loading of the foam during the Cyclic Compression test. Theenergy return of a foam is the integral of the force displacement curveduring unloading of the foam during the Cyclic Compression test. Thethermoplastic elastomer foam portion of the article or component of anarticle, including a thermoplastic polyester foam portion, can have anenergy return of about 200 millijoules (mJ) to about 1200 mJ, or fromabout 400 mJ to about 1000 mJ, or from about 600 mJ to about 800 mJ,when determined using the Cyclic Compression Test for a Sample with a 45millimeter diameter cylindrical sample. The thermoplastic elastomer foamportion of the article or component of an article (e.g., footwear solefor a Men's US Size 10) can have an energy input of about 2000millijoules (mJ) to about 9000 mJ, or from about 3000 mJ to about 8000mJ, or from about 4500 mJ to about 6500 mJ, when determined using theCyclic Compression Test for a Foot Form with the foot form sample. Thethermoplastic elastomer foam article or article component can be formedby injection molding without a subsequent compression molding step. Thethermoplastic elastomer foam can have an open-cell foam structure. Thethermoplastic elastomer foam can be the foamed product of foaming athermoplastic elastomer composition comprising less than 10 weightpercent, or less than 5 weight percent, or less than 1 weight percent ofnon-polymeric ingredients based on a total weight of the thermoplasticelastomer composition.

The energy efficiency (EE), a measure of the percentage of energy of thethermoplastic elastomer foam portion of the article or component,including a thermoplastic polyester foam portion, returns when it isreleased after being compressed under load, which can provide improvedperformance for athletic footwear, e.g., for reducing energy loss ordissipation when running. This is especially true for running and otherathletic footwear. In some aspects, the thermoplastic elastomer foamportion of the articles and components provided herein have an energyefficiency of at least 50 percent, or at least 60 percent, or at least70 percent, or at least about 75 percent, or at least about 80 percent,or at least about 85 percent, when determined using the CyclicCompression Test for a Sample with a 45 millimeter diameter cylindricalsample. The thermoplastic elastomer foam portion of the articles andcomponents provided herein can have an energy efficiency of at about 50percent to about 97 percent, or about 60 percent to about 95 percent, orabout 60 percent to about 90 percent, or about 60 percent to about 85percent, or about 65 percent to about 85 percent, or about 70 percent toabout 85 percent, or about 70 percent to about 90 percent, or about 70percent to about 95 percent, when determined using the CyclicCompression Test for a Sample with a 45 millimeter diameter cylindricalsample. The thermoplastic elastomer foam article or article componentcan be formed by injection molding without a subsequent compressionmolding step. The thermoplastic elastomer foam can have an open-cellfoam structure. The thermoplastic elastomer foam can be the foamedproduct of foaming a thermoplastic elastomer composition comprising lessthan 10 weight percent, or less than 5 weight percent, or less than 1weight percent of non-polymeric ingredients based on a total weight ofthe thermoplastic elastomer composition.

The resulting foams can have a multicellular closed-cell or open-cellfoam structure. Cells are the hollow structures formed during thefoaming process, in which bubbles are formed in the thermoplasticelastomeric composition by the foaming agents. The cell walls aregenerally defined by the thermoplastic elastomeric composition. “Closedcells” form an individual volume that is fully enclosed and that is notin fluid communication with an adjoining individual volume. “Closed-cellstructures” refer to foam structures in which at least 50 percent ormore of the cells are closed cells, or at least 60 percent or more ofthe cells are closed cells, or at least 80 percent of the cells areclosed cells, or at least 90 percent of the cells are closed cells, orat least 95 percent of the cells are closed cells. “Open-cellstructures” refer to foam structures in which less than 50 percent, orless than 40 percent, or less than 20 percent, or less than 10 percent,or less than 5 percent or less than 4 percent, or less than 3 percent orless than 1 percent of the cells are closed cells.

The disclosed open-cell and closed-cell thermoplastic elastomer foamsmay have an average cell size (e.g., maximum width or length) linearlymeasured from one side of the cell to an opposing side of the cell. Forexample, in some aspects of this disclosure, open-cell and closed-cellthermoplastic elastomer foams may have an average cell size of fromabout 50 micrometers to about 1000 micrometers, or from about 80micrometers to about 800 micrometers, or from about 100 micrometers toabout 500 micrometers. These are example cell sizes of one aspect ofthis disclosure in which foams form portions of a footwear article, andin other aspects the cell sizes may be larger or smaller when foams formother footwear articles. In addition, open-cell and closed-cellthermoplastic elastomer foams may form all or a portion of anon-footwear article, and in those instances, the foams may have a celldiameter including these example cell sizes, smaller than these examplecell sizes, larger than these example cell sizes, or any combinationthereof.

For both open-cell and closed-cell structures, the proportion of cellsin the thermoplastic elastomer foam having a cell diameter of about 50micrometers to about 1000 micrometers is preferably not less than 40percent relative to all the cells, or not less than 50 percent or notless than 60 percent relative to all the cells. If the proportion ofcells is less than 40 percent, the cell structure will tend to benonuniform and/or have a coarse cell structure. As used herein, a“coarse cell structure” refers to a foam structure in which the averagecell diameter is greater than 1 millimeter, and/or for greater than 20percent of the cells, a 1 millimeter line drawn across the largestdimension of the cell, will not cross a cell wall or a strut (i.e., anopen cell wall or portion thereof).

The number of open cells and/or closed cells and cell diameter of thecells of the foam can be determined visually, for example by capturingan image of a cut surface with a camera or digital microscope,determining the number of cells, number of open cells and/or number ofclosed cells, and determining an area of a cell, and converting it tothe equivalent circle diameter.

Methods of Manufacturing Disclosed Foams

In some examples, the disclosed foamed thermoplastic elastomercompositions can be prepared by various methods as disclosed herein andas known in the art. That is, disclosed articles or components ofarticles such as midsoles, midsole components, inserts and insertcomponents can be prepared by injection molding a melt compositioncomprising a thermoplastic elastomer composition as described hereinusing a physical foaming agent, using a combination of a physicalfoaming agent and a chemical foaming agent, or using only a chemicalfoaming agent. A disclosed foam component, e.g., a disclosed foamarticle or component, can be prepared by the methods disclosed hereinbelow.

Disclosed herein are methods for making a foam article or component, themethod comprising: forming a mixture of a molten thermoplastic elastomercomposition and a foaming agent; injecting the mixture into a moldcavity; foaming the thermoplastic elastomer composition, thereby forminga foamed thermoplastic elastomer composition; solidifying the foamedthermoplastic elastomer composition, thereby forming a foam articlehaving a multicellular foam structure; and removing the foam articlefrom the mold cavity. In some aspects, forming the mixture of thethermoplastic elastomer composition and the foaming agent comprisesforming a single-phase solution of a liquid, gas or supercritical fluidfoaming agent and the molten thermoplastic elastomer composition. Insome aspects, the mixture is a single-phase solution of supercriticalnitrogen or supercritical carbon dioxide and the thermoplastic elastomercomposition. In a particular example, the mixture is a single-phasesolution of supercritical nitrogen in a thermoplastic polyestercomposition. In some aspects, the thermoplastic elastomer compositioncomprises less than 10 weight percent, or less than 5 weight percent, orless than 1 weight percent of non-polymeric ingredients based on a totalweight of the thermoplastic elastomer composition. In such aspects,injecting the mixture into a mold cavity can comprise injecting thesingle-phase solution into a mold cavity, then cooling the single-phasesolution in the mold cavity prior to decreasing pressure in the moldcavity to a level at which the supercritical fluid phase transitions toa gas, and the gas drops out of solution in the molten polymer, forminggas bubbles in the molten polymer and foaming the molten polymer. Insome aspects, the foaming forms a foam having an open-cell foamstructure.

Also disclosed are methods for making a foam article or component, themethod comprising: forming a mixture of a molten thermoplastic elastomercomposition and a foaming agent; injecting the mixture into a moldcavity; foaming the molten thermoplastic elastomer composition in themold cavity, thereby forming a thermoplastic elastomer foam; solidifyingthe thermoplastic elastomer foam in the mold cavity, thereby forming amolded foam article comprising a thermoplastic elastomer compositionhaving a multicellular foam structure; and removing the molded foamarticle from the mold cavity. In some aspects, the temperature of themixture at the point that it is foamed in the mold cavity is from aboutthe melting temperature of the thermoplastic elastomer composition toabout 50 degrees C. above the tail temperature of the thermoplasticelastomer composition. In some aspects, the melting temperature of thethermoplastic elastomer composition is the melting temperature of apolymeric component of the thermoplastic elastomer composition. In otheraspects, the melting temperature of the thermoplastic elastomercomposition is the melting temperature of a thermoplastic elastomerpresent in the thermoplastic elastomer composition. In yet otheraspects, the melting temperature of the thermoplastic elastomer presentin the thermoplastic elastomer composition is the melting temperature ofthe thermoplastic elastomer having the highest melting temperature ofall polymers present in the polymeric component of the thermoplasticelastomer composition. In yet other aspects, the melting temperature isthe melting temperature of a thermoplastic polyester, such as apolyester elastomer, present in the thermoplastic elastomer composition.The foaming can occur when the mixture is at a foaming temperature,wherein the foaming temperature is a temperature from about the meltingtemperature of the thermoplastic elastomer to about 50 degrees C. abovethe tail temperature of the thermoplastic elastomer. In some aspects,forming the mixture of the thermoplastic elastomer composition and afoaming agent comprises forming a single-phase solution of asupercritical fluid and the molten thermoplastic elastomer composition.The thermoplastic elastomer composition can comprise less than 10 weightpercent, or less than 5 weight percent, or less than 1 weight percent ofnon-polymeric ingredients based on a total weight of the thermoplasticelastomer composition. If more than one thermoplastic elastomer ispresent in the thermoplastic elastomer composition, the meltingtemperature can be the highest melting temperature of the thermoplasticelastomers present in the composition. In such aspects, injecting themixture into a mold cavity can comprise injecting the single-phasesolution into a mold cavity, then cooling the single-phase solution inthe mold cavity prior to decreasing pressure in the mold cavity to alevel at which the supercritical fluid phase transitions to a gas, andthe gas drops out of solution in the thermoplastic elastomercomposition, forming gas bubbles in the thermoplastic elastomercomposition and foaming the thermoplastic elastomer. The foaming canform a foam having an open-cell foam structure.

Dynamic scanning calorimetry (DSC) is used to determine the meltingtemperature and the tail temperature of the thermoplastic elastomercomposition, or of the polymeric component of the thermoplasticelastomer composition, or of an individual thermoplastic elastomerpresent in the thermoplastic elastomer composition, and an exemplarymethod is described herein below. Briefly, 10-30 mg pieces of undriedresin pellets are cycled from −90 degrees C. to 225 degrees C. at 20degrees C./min and cooled to −90 degrees C. at 10 degrees C./min. Insome instances, experiments are run using a heat-cool-heat profile witha ramp rate of 10 degrees C. per min, minimum temperature of 0 degreesC. and maximum temperature of 250 degrees C. Analyses should bedetermined in duplicate. The melting temperature and glass transitiontemperature values are recorded from the second cycle. The melt “peak”is identified as the local maximum of the second heating cycle. If thereis more than one peak in the DSC curve, the peak occurring at hottertemperatures is chosen as the temperature reference. The tail isidentified as the intersection of the tangent of the line of the highertemperature side of the melt peak with the extrapolated baseline.

The disclosed foamed thermoplastic elastomer compositions can beprepared using a suitable injector. The injector can have a motor toturn a screw inside the injector. The injector may include a singlescrew or twin screws, and may include individual elements of varioussizes and pitches appropriate for mixing or kneading the specificmaterials used.

The various components included in the foamed thermoplastic elastomercompositions described herein can be added into the injector through oneor more ports. The various components can be added as a melt or asappropriately-sized solid particles, for example chips or pellets, whichmay be melted as they are mixed in the barrel of the injector. Thecontents of the injector can be heated to melt the composition. Aphysical foaming agent such as, for example, a supercritical fluid canbe added into the melt while it is present in the barrel of theinjector. In one example, thermoplastic polyester foam is prepared byusing a physical foaming agent which foams the composition in the moldcavity, and the resulting thermoplastic elastomer foam is thussubstantially free of unreacted chemical blowing agents or adecomposition or degradation product of a chemical blowing agent. Thethermoplastic elastomer composition can be added to the injector as amelt at a temperature close to the melting temperature of the polymericcomponent of the composition.

If a chemical foaming agent is used, the processing (melting)temperature used can be sufficiently below the temperature that wouldtrigger the chemical foaming agent. In order to foam the composition,the temperature near the exit of the injector or within the mold cavitycan be increased to a temperature close to or at the triggeringtemperature of the chemical foaming agent, thereby producing achemically foamed thermoplastic polyester foam as the composition exitsthe injector (e.g., as the composition is injected into a mold cavity),or within the mold cavity. Additionally or alternatively, thetemperature of the runners leading to the mold cavity or the mold cavityor both can be a temperature at or above the triggering temperature ofthe chemical foaming agent, thereby producing a chemically foamedthermoplastic elastomer foam within the runners and/or the mold cavity.

Alternatively or in addition, a physical foaming agent can be used tofoam the thermoplastic elastomer composition to form a physically foamedthermoplastic elastomer foam, or a physically and chemically foamedthermoplastic elastomer foam. For example, a supercritical fluid such assupercritical carbon dioxide or supercritical nitrogen can be mixed withthe molten thermoplastic elastomer composition in the barrel of theinjector to form a single-phase solution. A pressure drop can be used tocause the supercritical fluid to transition to the gas phase and foamthe thermoplastic elastomer composition. In one aspect, a gascounter-pressure can be applied to the mold cavity and to the runnersleading to the mold cavity. The counter pressure can be a pressuresufficiently high to keep the supercritical fluid in solution within therunners and the mold cavity. Once a dose of the single-phase solution isin the mold cavity, the counter-pressure within the mold cavity can bedecreased to a level at which the supercritical fluid phase transitionsto a gas and drops out of solution in the molten thermoplastic elastomercomposition, forming gas bubbles in the thermoplastic elastomercomposition and foaming the thermoplastic elastomer composition in themold cavity. In one aspect the thermoplastic elastomer compositioncomprises less than 10 weight percent, or less than 5 weight percent, orless than 1 weight percent of non-polymeric ingredients based on a totalweight of the thermoplastic elastomer composition, and the multicellularfoam has an open-cell structure.

The articles, cushioning elements, or components of articles such asmidsoles, midsole components, inserts and insert components can beprepared by injection molding a thermoplastic elastomer compositiondescribed herein using a physical foaming agent. The injection moldingprocess can use a screw-type injector that allows for maintaining andcontrolling the pressure in the injector barrel. The injection moldingmachine can allow metering and delivering a supercritical fluid such ascarbon dioxide or nitrogen into the thermoplastic elastomer compositionprior to injection. The supercritical fluid can be mixed into thethermoplastic elastomer composition within the injection barrel and theninjected into the mold cavity. When the temperature and/or pressure isaltered to the point that the solubility of the supercritical fluid inthe molten thermoplastic elastomer composition is altered and thesupercritical fluid transitions to the gas phase, these physicalprocesses will cause expansion (foaming) of the molten thermoplasticelastomer composition. The injection molding process can includephysical foaming of the compositions described herein using an injectionmolding process which forms a multicellular foam structure, such as, forexample the “MUCELL” process (Trexel Inc., Wilmington, Massachusetts,USA).

The thermoplastic elastomer foams described herein can be made using aprocess that involves impregnating a thermoplastic elastomer composition(e.g., at or above a softening temperature of the composition) with aphysical foaming agent at a first concentration or first pressure. Asused herein, the term “impregnating” generally means dissolving orsuspending a physical foaming agent in a composition. The impregnatedcomposition can then be foamed, or can be cooled (when applicable) andre-softened (when applicable) for foaming at a later time. In someaspects, the impregnated molten thermoplastic elastomer compositionforms a single-phase solution comprising a supercritical fluid (e.g.,carbon dioxide or nitrogen) dissolved in the molten thermoplasticelastomer composition. In one aspect, the thermoplastic elastomercomposition comprises less than 10 weight percent, or less than 5 weightpercent, or less than 1 weight percent of non-polymeric ingredientsbased on a total weight of the thermoplastic elastomer composition.

The impregnated thermoplastic elastomer composition (e.g., thesingle-phase solution) is foamed by reducing the solubility of thephysical foaming agent in the thermoplastic elastomer compositionthrough pressure and/or temperature changes. The pressure and/ortemperature change can occur immediately after the impregnatedcomposition exits the injector or the injection barrel, or can occur inthe runners leading to the mold cavity, or can occur in the mold cavity.For example, the system can include hot runners or gas counter-pressureor both, which control the temperature and pressure under which theimpregnated composition is held, up to and including the point at whichthe composition enters the mold cavity. In some aspects, the temperatureand pressure under which the impregnated composition is held arecontrolled such that the impregnated composition remains a single-phasesolution up to and including the point it enters the mold cavity. Oncethe single-phase solution has flowed into the mold cavity, thetemperature or the pressure or both can be altered to reduce thesolubility of the supercritical fluid in the molten thermoplasticelastomer composition, causing the molten thermoplastic elastomercomposition to expand into a foam, including a foam having an open-cellfoam structure. The reduction in solubility of the physical foamingagent can release additional amounts of gas (e.g., to create a secondaryexpansion of a partially-foamed thermoplastic elastomer composition), tofurther expand the composition, forming a foam structure (e.g., a foamhaving a multicellular structure). Alternatively or additionally, achemical blowing agent can be activated in the thermoplastic elastomercomposition in the mold cavity to create a secondary expansion of apartially-foamed thermoplastic elastomer composition.

Chemical foaming agents may be endothermic or exothermic, which refersto a type of decomposition or degradation they undergo to produce thegas used to produce the foam. The decomposition or degradation may betriggered by thermal energy present in the molding system. Endothermicfoaming agents absorb energy and typically release a gas, such as carbondioxide, upon decomposition. Exothermic foaming agents release energyand generate a gas, such as nitrogen, when decomposed. Regardless of thechemical foaming agent used, thermal variables of the thermoplasticelastomer composition being foamed and thermal variables of the foamingagent to be decomposed or degraded are coupled together such thatprocess parameters are selected so that the thermoplastic elastomercomposition can be foamed and molded and the foaming agent can decomposeor degrade at an appropriate phase of the foaming and molding process.

Thermoplastic Elastomer Composition

Thermoplastic elastomer compositions disclosed herein include one ormore thermoplastic elastomers. The one or more thermoplastic elastomerscan be one or more thermoplastic polyester elastomers. In some aspects,the thermoplastic elastomer composition includes at least 90 percent, orat least 95 weight percent, or at least 99 weight percent of athermoplastic resin component, based on the total weight of thethermoplastic elastomer composition, where thermoplastic resin componentincludes all the polymers present in the composition. Thermoplasticresin component comprises one or more thermoplastic elastomers.Thermoplastic resin component can comprise at least one thermoplasticpolyester elastomer. Thermoplastic resin component can comprise morethan one thermoplastic polyester elastomer. Thermoplastic resincomponent can comprise one or more thermoplastic polyester elastomer,and one or more thermoplastic polyester which is not an elastomer. Insome aspects, thermoplastic resin component comprises the one or morethermoplastic polyester, and further comprises one or more thermoplasticpolymers each of which is not a polyester. The one or more thermoplasticpolymers each of which is not a polyester can each be a thermoplasticelastomer. Alternatively, in other aspects, thermoplastic resincomponent consists essentially of the one or more thermoplasticelastomer. Optionally, thermoplastic resin component can consistessentially of one or more thermoplastic polyester elastomer. In someaspects, the thermoplastic elastomer composition comprises less than 10weight percent, or less than 5 weight percent, or less than 1 weightpercent of non-polymeric ingredients based on the total weight of thethermoplastic elastomer composition. In some aspects, the thermoplasticelastomer composition is substantially free of non-polymeric nucleatingagents, or is substantially free of non-polymeric fillers, or issubstantially free of coloring agents, or is substantially free ofnon-polymeric processing aids, or is substantially free of bothnon-polymeric nucleating agents and non-polymeric fillers, or issubstantially free of non-polymeric nucleating agents, non-polymericfillers, coloring agents, and non-polymeric processing aids. In somesuch aspects, the thermoplastic elastomer composition comprises lessthan 10 weight percent, or less than 5 weight percent, or less than 1weight percent of solid coloring agents, based on the total weight ofthe thermoplastic elastomer composition. In one aspect, thethermoplastic elastomer composition consists essentially of one or morethermoplastic elastomers. In another aspect, the thermoplastic elastomercomposition consists essentially of one or more thermoplastic polyesterelastomers. It should be understood that a thermoplastic polyesterelastomer can refer to a thermoplastic polyester homopolymer elastomer,a thermoplastic copolyester elastomer, or both. In aspects, thethermoplastic copolyester elastomer can include copolyesters having twoor more types of polyester monomeric segments, or copolyesterscomprising polyester monomeric segments and one or more non-polyestermonomeric segments.

In some aspects, the resin component of the thermoplastic elastomercomposition, which is comprised of all the polymeric materials presentin thermoplastic polyester composition, consists essentially of the oneor more thermoplastic elastomers, or consists essentially of the one ormore thermoplastic polyesters. Thermoplastic polyesters can includechain units derived from one or more olefins and chain units derivedfrom one or more ethylenically-unsaturated acid groups, in aspects.

The thermoplastic elastomer compositions can have a melt flow index offrom about 5 to about 40, or about 10 to about 20, or about 20 to about30 as determined at 210 degrees C. using a 2.16 kilogram weight.Alternatively or additionally, the thermoplastic elastomer compositionscan have a melt flow index of from about 5 to about 40, or about 10about 20, or about 20 to about 30 as determined at 220 degrees C. usinga 2.16 kilogram weight. Alternatively or additionally, the thermoplasticelastomer compositions can have a melt flow index of from about 5 toabout 40, or about 10 to about 20, or about 20 to about 30 as determinedat 230 degrees C. using a 2.16 kilogram weight.

The thermoplastic elastomer, including thermoplastic polyester, can havea weight average molecular weight of about 50,000 Daltons to about1,000,000 Daltons; or about 50,000 Daltons to about 500,000 Daltons; orabout 75,000 Daltons to about 300,000 Daltons; or about 100,000 Daltonsto about 250,000 Daltons; or about 100,000 Daltons to about 500,000Daltons.

The thermoplastic elastomers, including thermoplastic copolyesters, canbe terpolymers. In some aspects, thermoplastic copolyesters can beterpolymers of moieties derived from ethylene, acrylic acid, and methylacrylate or butyl acrylate. In some aspects, a ratio of a total parts byweight of the acrylic acid in thermoplastic copolyesters to a totalweight of thermoplastic copolyesters is about 0.05 to about 0.6, orabout 0.1 to about 0.6, or about 0.1 to about 0.5, or about 0.15 toabout 0.5, or about 0.2 to about 0.5.

The thermoplastic elastomers can be terpolymers comprising a pluralityof first segments, a plurality of second segments, and a plurality ofthird segments. In some aspects, the thermoplastic elastomer is athermoplastic copolyester comprising: (a) a plurality of first segments,each first segment derived from a dihydroxy-terminated polydiol; (b) aplurality of second segments, each second segment derived from a diol;and (c) a plurality of third segments, each third segment derived froman aromatic dicarboxylic acid. In various aspects, thermoplasticcopolyester is a block copolymer. In some aspects, thermoplasticcopolyester is a segmented copolymer. In further aspects, thermoplasticcopolyester is a random copolymer. In still further aspects,thermoplastic copolyester is a condensation copolymer.

The thermoplastic elastomer, including thermoplastic copolyester, canhave a ratio of first segments to third segments from about 1:1 to about1:5 based on the weight of each of the first segments and the thirdsegments; or about 1:1 to about 1:4 based on the weight of each of thefirst segments and the third segments; or about 1:1 to about 1:2 basedon the weight of each of the first segments and the third segments; orabout 1:1 to about 1:3 based on the weight of each of the first segmentsand the third segments.

The thermoplastic elastomer, including thermoplastic copolyester, canhave a ratio of second segments to third segments from about 1:1 toabout 1:2 based on the weight of each of the first segments and thethird segments; or about 1:1 to about 1:1.52 based on the weight of eachof the first segments and the third segment.

The thermoplastic elastomer, including thermoplastic copolyester, canhave first segments derived from a poly(alkylene oxide)diol having anumber-average molecular weight of about 250 Daltons to about 6000Daltons; or about 400 Daltons to about 6,000 Daltons; or about 350Daltons to about 5,000 Daltons; or about 500 Daltons to about 3,000Daltons; or about 2,000 Daltons to about 3,000 Daltons.

The thermoplastic elastomer, including thermoplastic copolyester, canhave first segments derived from a poly(alkylene oxide)diol such aspoly(ethylene ether)diol; poly(propylene ether)diol; poly(tetramethyleneether)diol; poly(pentamethylene ether)diol; poly(hexamethyleneether)diol; poly(heptamethylene ether)diol; poly(octamethyleneether)diol; poly(nonamethylene ether)diol; poly(decamethyleneether)diol; or mixtures thereof. In a still further aspect,thermoplastic copolyester can have first segments derived from apoly(alkylene oxide)diol such as poly(ethylene ether)diol;poly(propylene ether)diol; poly(tetramethylene ether)diol;poly(pentamethylene ether)diol; poly(hexamethylene ether)diol. In a yetfurther aspect, thermoplastic copolyester can have first segmentsderived from a poly(tetramethylene ether)diol.

The thermoplastic elastomer, including thermoplastic copolyester, canhave second segments derived from a diol having a molecular weight ofless than about 250. The diol from which the second segments are derivedcan be a C2-C8 diol. In a still further aspect, the second segments canbe derived from ethanediol; propanediol; butanediol; pentanediol;2-methyl propanediol; 2,2-dimethyl propanediol; hexanediol;1,2-dihydroxy cyclohexane; 1,3-dihydroxy cyclohexane; 1,4-dihydroxycyclohexane; and mixtures thereof. In a yet further aspect, the secondsegments can be derived from 1,2-ethanediol, 1,3-propanediol,1,4-butanediol, 1,6-hexanediol, and mixtures thereof. In an even furtheraspect, the second segments can be derived from 1,2-ethanediol. In astill further aspect, the second segments can be derived from1,4-butanediol.

The thermoplastic elastomer, including the copolyester, can have thirdsegments derived from an aromatic C5-C16 dicarboxylic acid. The aromaticC5-C16 dicarboxylic acid can have a molecular weight less than about 300Daltons; about 120 Daltons to about 200 Daltons; or a value or values ofmolecular weight within any of the foregoing ranges or a molecularweight range encompassing any sub-range of the foregoing ranges. In someinstances, the aromatic C5-C16 dicarboxylic acid is terephthalic acid,phthalic acid, isophthalic acid, or a derivative thereof. In a stillfurther aspect, the aromatic C5-C16 dicarboxylic acid is a diesterderivative of the terephthalic acid, phthalic acid, or isophthalic acid.In a yet further aspect, the aromatic C5-C16 dicarboxylic acid isterephthalic acid or the dimethyl ester derivative thereof.

Thermoplastic copolyester can comprise: (a) a plurality of firstcopolyester units, each first copolyester unit of the pluralitycomprising the first segment derived from a dihydroxy-terminatedpolydiol and the third segment derived from an aromatic dicarboxylicacid, wherein the first copolyester unit has a structure represented bya Formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide)diol of the first segment, whereinthe poly(alkylene oxide)diol of the first segment is a poly(alkyleneoxide)diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and (b) a plurality of second copolyester units, each secondcopolyester unit of the plurality comprising the second segment derivedfrom a diol and the third segment derived from an aromatic dicarboxylicacid, wherein the second copolyester unit has a structure represented bya Formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

Thermoplastic copolyester can comprise a plurality of first copolyesterunits having a structure represented by a Formula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, in the foregoing formula,z is an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any set or range of theforegoing integer values. In some aspects, R is hydrogen. In a stillfurther aspect, R is methyl. In some instances, R is hydrogen and y isan integer having a value of 1, 2, or 3. Alternatively, in otherinstances, R is methyl and y is an integer having a value of 1.

Thermoplastic copolyester can comprise a plurality of first copolyesterunits having a structure represented by a Formula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, in the foregoing formula,z is an integer having a value from 5 to 60; or an integer having avalue from 5 to 50; or an integer having a value from 5 to 40; or aninteger having a value from 4 to 30; or an integer having a value from 4to 20; or an integer having a value from 2 to 10.

Thermoplastic copolyester can comprise a plurality of first copolyesterunits having a weight average molecular weight from about 400 Daltons toabout 6,000 Daltons; or about 400 Daltons to about 5,000 Daltons; orabout 400 Daltons to about 4,000 Daltons; or about 400 Daltons to about3,000 Daltons; or about 500 Daltons to about 6,000 Daltons; or about 500Daltons to about 5,000 Daltons; or about 500 Daltons to about 4,000Daltons; or about 500 Daltons to about 3,000 Daltons; or about 600Daltons to about 6,000 Daltons; or about 600 Daltons to about 5,000Daltons; or about 600 Daltons to about 4,000 Daltons; or about 600Daltons to about 3,000 Daltons; or about 2,000 Daltons to about 3,000Daltons.

Thermoplastic copolyester can comprise a plurality of second copolyesterunits, each second copolyester unit of the plurality having a structurerepresented by a Formula 5:

wherein x is an integer having a value from 1 to 20; wherein the foamarticle has a multicellular closed-cell or open-cell foam structure. Insome aspects, in the foregoing formula, x is an integer having a valuefrom 2 to 18; 2 to 17; 2 to 16; 2 to 15; 2 to 14; 2 to 13; 2 to 12; 2 to11; 2 to 10; 2 to 9; 2 to 8; 2 to 7; 2 to 6; 2 to 5; 2 to 4; or x can beany integer value or set of integer values within the foregoing rangesor values, or any range of integer values encompassing a sub-range ofthe foregoing integer value ranges. In a further aspect, x is an integerhaving a value of 2, 3, or 4.

Thermoplastic copolyester can comprise a plurality of second copolyesterunits, each second copolyester unit of the plurality having a structurerepresented by a Formula 6:

Thermoplastic copolyester can comprise a weight percent range of theplurality of first copolyester units based on total weight ofthermoplastic copolyester such that the weight percent range is about 30weight percent to about 80 weight percent; or about 40 weight percent toabout 80 weight percent; or about 50 weight percent to about 80 weightpercent; or about 30 weight percent to about 70 weight percent; or about40 weight percent to about 70 weight percent; or about 50 weight percentto about 70 weight percent; or about 40 weight percent to about 65weight percent; or about 45 weight percent to about 65 weight percent;or about 50 weight percent to about 65 weight; or about 55 weightpercent to about 65 weight percent; or about 40 weight percent to about60 weight percent; or about 45 weight percent to about 60 weightpercent; or about 50 weight percent to about 60 weight percent; or about55 weight percent to about 60 weight percent.

In some aspects, the thermoplastic elastomer, including thermoplasticcopolyester, can comprise phase separated domains. For example, aplurality of first segments derived from a dihydroxy-terminated polydiolcan phase-separate into domains comprising primarily the first segments.Moreover, a plurality of second segments derived from a diol canphase-separate into domains comprising primarily the second segments. Inother aspects, thermoplastic copolyester can comprise phase-separateddomains comprising primarily of a plurality of first copolyester units,each first copolyester unit of the plurality comprising the firstsegment derived from a dihydroxy-terminated polydiol and the thirdsegment derived from an aromatic dicarboxylic acid, wherein the firstcopolyester unit has a structure represented by a Formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide)diol of the first segment, whereinthe poly(alkylene oxide)diol of the first segment is a poly(alkyleneoxide)diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and other phase-separated domains comprising primarily of aplurality of second copolyester units, each second copolyester unit ofthe plurality comprising the second segment derived from a diol and thethird segment derived from an aromatic dicarboxylic acid, wherein thesecond copolyester unit has a structure represented by a Formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

In other aspects, thermoplastic copolyester can comprise phase-separateddomains comprising primarily of a plurality of first copolyester units,each first copolyester unit of the plurality having a structurerepresented by a Formula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, in the foregoing formula,z is an integer having a value from 5 to 60; an integer having a valuefrom 5 to 50; an integer having a value from 5 to 40; an integer havinga value from 4 to 30; an integer having a value from 4 to 20; an integerhaving a value from 2 to 10; or z can be any set or range of theforegoing integer values. In some aspects, R is hydrogen. In a stillfurther aspect, R is methyl. In some instances, R is hydrogen and y isan integer having a value of 1, 2, or 3. Alternatively, in otherinstances, R is methyl and y is an integer having a value of 1.

In other aspects, thermoplastic copolyester can comprise phase-separateddomains comprising primarily of a plurality of first copolyester units,each first copolyester unit of the plurality having a structurerepresented by a Formula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Insome aspects, in the foregoing formula, y can be an integer having avalue of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range ofthe foregoing integer values. In some aspects, in the foregoing formula,z is an integer having a value from 5 to 60; or an integer having avalue from 5 to 50; or an integer having a value from 5 to 40; or aninteger having a value from 4 to 30; or an integer having a value from 4to 20; or an integer having a value from 2 to 10.

Thermoplastic copolyester can comprise phase-separated domainscomprising primarily of a plurality of first copolyester units having aweight average molecular weight from about 400 Daltons to about 6,000Daltons; or about 400 Daltons to about 5,000 Daltons; or about 400Daltons to about 4,000 Daltons; or about 400 Daltons to about 3,000Daltons; or about 500 Daltons to about 6,000 Daltons; or about 500Daltons to about 5,000 Daltons; or about 500 Daltons to about 4,000Daltons; or about 500 Daltons to about 3,000 Daltons; or about 600Daltons to about 6,000 Daltons; or about 600 Daltons to about 5,000Daltons; or about 600 Daltons to about 4,000 Daltons; or about 600Daltons to about 3,000 Daltons; or about 2,000 Daltons to about 3,000Daltons

In other aspects, thermoplastic copolyester can comprise phase-separateddomains comprising a plurality of second copolyester units, each secondcopolyester unit of the plurality having a structure represented by aFormula 5:

wherein x is an integer having a value from 1 to 20; wherein the foamarticle has a multicellular closed-cell or open-cell foam structure. Insome aspects, in the foregoing formula, x is an integer having a valuefrom 2 to 18; or 2 to 17; or 2 to 16; or 2 to 15; or 2 to 14; or 2 to13; or 2 to 12; or 2 to 11; or 2 to 10; or 2 to 9; or 2 to 8; or 2 to 7;or 2 to 6; or 2 to 5; or 2 to 4.

In other aspects, thermoplastic copolyester can comprise phase-separateddomains comprising a plurality of second copolyester units, each secondcopolyester unit of the plurality having a structure represented by aFormula 6:

Thermoplastic copolyester can comprise phase-separated domainscomprising a weight percent range of the plurality of first copolyesterunits based on total weight of thermoplastic copolyester such that theweight percent range is about 30 weight percent to about 80 weightpercent; or about 40 weight percent to about 80 weight percent; or about50 weight percent to about 80 weight percent; or about 30 weight percentto about 70 weight percent; or about 40 weight percent to about 70weight percent; or about 50 weight percent to about 70 weight percent;or about 40 weight percent to about 65 weight percent; or about 45weight percent to about 65 weight percent; or about 50 weight percent toabout 65 weight percent; or about 55 weight percent to about 65 weightpercent; or about 40 weight percent to about 60 weight percent; or about45 weight percent to about 60 weight percent; or about 50 weight percentto about 60 weight percent; or about 55 weight percent to about 60weight percent.

In various aspects, the thermoplastic elastomer composition can includeone or more thermoplastic polyester homopolymer, where the thermoplasticpolyester homopolymer comprises any of the polyester monomeric segmentsor units disclosed herein or modifications thereof. In the same oralternative aspects, the thermoplastic elastomer composition can includeone or more thermoplastic polyester homopolymer, where the thermoplasticpolyester homopolymer comprises any polyester homopolymer exhibiting anyor all of the properties and parameters discussed herein with respect tothermoplastic elastomers and/or the thermoplastic elastomer composition.

The disclosed thermoplastic elastomer composition, the polymericcomponent of the composition or an individual thermoplastic elastomer inneat form can be characterized by one or more properties. In someaspects, the thermoplastic elastomer composition or the polymericcomponent, or the polymer has a maximum load of about 10 newtons toabout 100 newtons, or from about 15 newtons to about 50 newtons, or fromabout 20 newtons to about 40 newtons, when determined using the CyclicTensile Test method described herein.

The tensile strength of the thermoplastic elastomer composition or ofthe polymeric component of the thermoplastic elastomer composition or ofa thermoplastic elastomer in neat form is another important physicalcharacteristic. The thermoplastic elastomer composition or polymericcomponent or elastomer can have a tensile strength of from 5 kilogramsper square centimeter to 25 kilograms per square centimeter, or of from10 kilograms per square centimeter to 23 kilograms per squarecentimeter, or of from 15 kilograms per square centimeter to 22kilograms per square centimeter, when determined using the CyclicTensile Test method described herein.

The thermoplastic elastomer composition or polymeric component of thethermoplastic elastomer composition or a thermoplastic elastomer in neatform can have a tensile modulus of about 2 megapascals to about 20megapascals or from about 5 megapascals to about 15 megapascals whendetermined using the Cyclic Tensile Test method described herein.

Exemplary, but non-limiting, thermoplastic elastomers, includingthermoplastic polyesters, that can be used in the disclosed methods,foams, and articles include “HYTREL” 3078, “HYTREL” 4068, and “HYTREL”4556 (DuPont, Wilmington, Delaware, USA); “PELPRENE” P30B, P40B, andP40H (Toyobo U.S.A. Inc., New York, New York, USA); “TRIEL” 5300,“TRIEL” 5400, and blends thereof (Samyang Corporation, Korea); “KEYFLEX”BT1028D, BT1033D, BT1035D, BT1040D, BT1045D, and BT1047D (LG Chem,Korea); and “KOPEL” KP3340, KP3346, KP3347 (Kolon Plastics, Inc.,Korea).

The disclosed thermoplastic elastomer compositions can further includeone or more ionomers, such as any of the “SURLYN” polymers (DuPont,Wilmington, Delaware, USA). Foams as described herein can be made by aprocess/method including receiving a composition described herein, andphysically foaming the composition to form a thermoplastic elastomerfoam having a density of about 0.7 gram per cubic centimeter or less, or0.5 gram per cubic centimeter or less, or 0.4 gram per cubic centimeteror less, or 0.3 gram per cubic centimeter or less.

The disclosed thermoplastic elastomer compositions can further includeone or more thermoplastic polyurethanes, such as “FORTIMO” (MitsuiChemicals, Inc., Tokyo, Japan); “TEXIN” (Covestro LLC, Pittsburgh,Pennsylvania, USA); and “BOUNCELL-X” (Lubrizol Advanced Materials, Inc.,Brecksville, Ohio, USA).

The disclosed thermoplastic elastomer compositions can further includeone or more olefinic polymers. Olefinic polymers can includeethylene-based copolymers, propylene-based copolymers, and butene-basedcopolymers. In some aspects, the olefinic polymer is an ethylene-basedcopolymer such as a styrene-ethylene/butylene-styrene (SEBS) copolymer;an ethylene-propylene diene monomer (EPDM) copolymer; an ethylene-vinylacetate (EVA) copolymer; an ethylene alkyl acrylate (EAA) copolymer; anethylene alkyl methacrylate (EAMA) copolymer; any copolymer thereof, andany blend thereof. In some aspects, a ratio V of a total parts by weightof the olefinic polymers present in the composition to a total parts byweight of thermoplastic polyesters in the composition is about 0.0 toabout 0.6, or about 0.0 to about 0.4, or about 0.01 to about 0.4, orabout 0.01 to about 0.6, or about 0.1 to about 0.4.

The disclosed thermoplastic elastomer compositions can further includean ethylene-vinyl acetate (EVA) copolymer. The ethylene-vinyl acetate(EVA) copolymer can have a range of vinyl acetate contents, for exampleabout 50 percent to about 90 percent, or about 50 percent to about 80percent, or about 5 percent to about 50 percent, or about 10 percent toabout 45 percent, or about 10 percent to about 30 percent, or about 30percent to about 45 percent, or about 20 percent to about 35 percent,based on the weight of the copolymer.

Thermoplastic Elastomer Composition Characterization

Component Sampling Procedure

This procedure can be used to obtain a sample of a foam composition ormaterial when the composition or material is incorporated into acomponent such as a sole structure or midsole or outsole of an articleof footwear. A sample of the component which includes the composition ormaterial is obtained as formed into the component, or cut from thearticle of footwear using a blade. This process is performed byseparating the component from an associated footwear upper, if present,and removing any materials from the article's top surface (e.g.,corresponding to the top surface). For example, the article's topsurface can be skinned, abraded, scraped, or otherwise cleaned to removeany upper adhesives, yarns, fibers, foams, and the like that couldpotentially interfere with the test results.

The resulting component sample includes the composition or material. Assuch, any test using a Component Sampling Procedure can simulate how thecomposition or material will perform as part of an article of footwear.As specified by the test method, the component may be tested as a fullcomponent (e.g., full midsole component), or it can be extracted as asample having a certain geometry. A sample of a component is taken at alocation along the component that provides a substantially constantthickness for the component (within plus or minus 10 percent of theaverage thickness), such as in a forefoot region, mid-foot region, or aheel region of the article. Unless otherwise specified, the desiredharvested geometry is a cylindrical puck with a 45-millimeter diameterand a cylinder height of at least about 10 millimeters, preferably fromabout 20 to 25 millimeters.

Density Test

The density is measured for samples taken using the Component SamplingProcedure, using a digital balance or a Densicom Tester (Qualitest,Plantation, Florida, USA). For each sample a sample volume is determinedin cubic centimeters, and then each sample is weighed (g). The densityof the sample is the mass divided by the sample volume, given ingrams/cubic centimeters.

Specific Gravity Test

This test is appropriate for testing closed-cell foams, and samples ofopen-cell foams having a substantially uniform closed skin. The specificgravity (SG) is measured for samples taken using the Component SamplingProcedure, using a digital balance or a Densicom Tester (Qualitest,Plantation, Florida, USA). Each sample is weighed (g) and then issubmerged in a distilled water bath (at 22 degrees C. plus or minus 2degrees C.). To avoid errors, air bubbles on the surface of the samplesare removed, e.g., by wiping isopropyl alcohol on the sample beforeimmersing the sample in water, or using a brush after the sample isimmersed. The weight of the sample in the distilled water is recorded.The specific gravity is calculated with the following formula:

${S.G.} = \frac{{Weight}{of}{the}{sample}{in}{air}(g)}{{{Weight}{of}{the}{sample}{in}{air}(g)} - {{Weight}{of}{the}{sample}{in}{water}(g)}}$

Force/Displacement Test (Cyclic Compression Test for a Foot Form)

Force/displacement behavior for the foams and the foamed articles may bemeasured using a full midsole sample, a full outsole sample, a splitmidsole and/or a split midsole, tested using a foot form for impact toaccurately simulate full gate loading. For these tests, a US men's size10 midsole is tested, and a men's size 9 foot form used for impact, witha load of 2000N being applied to the midsole with the foot form at aloading rate of 5 Hz with a cyclic compression testing device such anInstron Electropuls E10000 (Instron, Norwood, Massachusetts, USA). Eachsample is compressed to the peak load at 5 Hz for 100 cycles. Energyinput (J), energy return (J), energy efficiency (energy return/energyinput), energy efficiency percentage (100*(energy return/energy input))and maximum displacement (mm) are measured from the force vs.displacement curves generated. Stiffness of a particular foam sample isthe maximum load divided by the displacement at the maximum load, givinga value in N/mm. The reported value for each metric is the average ofthe metrics from the 60^(th), 70^(th), 80^(th), and 90^(th) cycles.

Cyclic Compression Test for a Sample

Force/displacement behavior for the foams and the foamed articles mayalso, or alternatively, be measured using samples harvested from alarger component (e.g., cylindrical pucks harvested from a footwearmidsole), and a method for obtaining a sample is described in the“Component Sampling Procedure” portion of this disclosure. In onetesting methodology, when testing a sample (e.g., a cylindrical puckharvested from a larger component), the sample is tested along thelength axis of the part using compression platens that are at least 2×the diameter (e.g., of the cylindrical puck). Furthermore, the sample iscompressed to the peak load (e.g., 50% strain) at 5 Hz for 500 cycles.Stiffness, efficiency, and energy return are measured from the force vs.displacement curves for cycles 200, 300, 400, and 500, and the reportedvalue for each metric is the average of each metric between cycles 200,300, 400, and 500. Stiffness, efficiency, and energy return are definedin the following ways, with example property ranges (possibly dependenton sample geometries) provided in parentheses. Stiffness is the stressat the maximum strain divided by the maximum strain (e.g., 200-1000kPa). Efficiency is the integral of the unloading force-displacementcurve divided by the integral of the loading force-displacement curve(e.g., 0.50-0.97). Energy return is the integral of the unloading curve(e.g., 200-1200 mJ).

Cyclic Tensile Test

The cyclic tensile testing is carried out on solid samples preparedusing the Component Sampling Procedure, having a dog-bone shape asdescribed in ASTM D638 with a 2 mm thickness. In the test, the specimenis placed under a pre-load of 5 N. Strain is controlled to extend thesample to an extension 6 percent at a strain rate of 5 Hz. The stiffnessis the load at 6 percent strain divided by the extension at 6 percentstrain, giving a value in N/mm. The maximum load (N) observed over thetest cycle of 500 cycles is also recorded.

Durometer Hardness Test—Shore A

The test used to obtain the hardness values for the foam articles is asfollows. A flat foam sample is prepared using the Component SamplingProcedure, where the sample has a minimum of 6 mm thick for Shore Adurometer testing. If necessary, samples are stacked to make up theminimum thickness. Samples are large enough to allow all measurements tobe performed at a minimum of 12 mm from the edge of the sample and atleast 12 mm from any other measurement. Regions tested are flat andparallel with an area at least 6 mm in diameter. A minimum of fivehardness measurements are taken and tested using a 1 kilogram headweight.

Split Tear Test

The split tear test can determine the internal tear strength for a foammaterial. A sample may be provided using the Component SamplingProcedure. The sample is die cut into a rectangular shape having a widthof 1.54 centimeters and a length of 15.24 centimeters (1 inch by 6inches), and having a thickness of 10 millimeters, plus or minus 1millimeter. On one end, a cut is made into the sample that bisects thethickness, the cut extending the full width of the sample, and 3centimeters from the end of the sample. Starting from the end of thecut, 5 marks are placed along the length of the sample spaced 2centimeters apart. The cut ends of the sample are placed in the clampsof a tensile tester. Each section of the sample is held in a clamp insuch a manner that the original adjacent cut edges form a straight linejoining the centers of the clamps. The crosshead speed is set to 50millimeters per minute. The tear strength is measured throughout theseparation of the crossheads. If necessary, a sharp knife may be used tokeep separating the foam in the center of the sample, discarding thereadings caused by cutting of the knife. The lowest split tear strengthvalues are recorded for each of the five marked segments of the sample(between each of the 2-centimeter markings). An average split tearstrength value is recorded for each sample. If a segment of a sample hasan air bubble measuring more than 2 millimeters, the tear strength forthe segment is discarded, and the air bubble recorded as a test defect.If more than one segment of a sample has an air bubble measuring morethan 2 millimeters, the entire sample is discarded.

Energy Intensity

Energy intensity is a measure of the energy used in forming a particularfoam article in kilowatt hours (kW-h). To obtain the energy intensity,the energy required (in kW-H) to produce a run, or batch, of articles,such as cushioning elements (such as pairs of the midsole 122) is firstcalculated, determined or measured (from pellet to finished component).For example, for a physical foaming process the measured energy mayinclude the energy required for all energy consuming steps, such as:preheating the molds and hot runners (if utilized), melting the pellets,generating gas counter-pressure, injecting the molten plastic,introducing the supercritical fluid, cooling the molds and/orwork-pieces and ejecting the work-pieces from the mold. The overallenergy required to produce the run of cushioning element pairs is thendivided by the number of cushioning element pairs produced in the run.

Zero Shear Viscosity

The zero shear viscosity is determined using a flow curve obtained on arotational rheometer. Zero shear viscosity is determined as the apparentviscosity of the polymer melt measured at a shear rate of 1×10⁻² 1/swhen the polymer is heated to 10° C. above its melting temperature.Apparent viscosity is measured under continuous flow using a cone andplate rotational fixture. The temperature of the rotational fixture ismaintained at the polymer melt temperature. The gap and geometry of thecone are selected such that the measured torque is well within themeasuring limits of a rheometer.

Melt Flow Index Test

The melt flow index is determined using a sample prepared usingComponent Sampling Procedure, according to the test method detailed inASTM D1238-13 Standard Test Method for Melt Flow Rates of Thermoplasticsby Extrusion Plastometer, using Procedure A described therein. Briefly,the melt flow index measures the rate of extrusion of thermoplasticsthrough an orifice at a prescribed temperature and load. In the testmethod, approximately 7 grams of the sample is loaded into the barrel ofthe melt flow apparatus, which has been heated to a specifiedtemperature of 210 degrees C., 220 degrees C., or 230 degrees C. Aweight of 2.16 kilograms is applied to a plunger and the molten sampleis forced through the die. A timed extrudate is collected and weighed.Melt flow rate values are calculated in g/10 min, and are reported withthe specified temperature (i.e., 210, 220 or 230 degrees C.) and theweight applied to the plunger (i.e., 2.15 kilograms).

Representative Data

In the tables below, the foam of the midsole 122 is compared againstother representative foams (Foams A, B and C). The first tablerepresents data with a midsole, outsole and strobel as an assembly. Thesecond table represents data from the respective midsoles only. Thedensity is calculated as described above under the density test. Theenergy intensity (EI) is determined as described above under the energyintensity section. Energy Efficiency (EE)(the average EE is labeled“Avg. Efficiency” in the chart below), energy input, energy returned(ER), average maximum displacement, and average stiffness are determinedusing the Force/Displacement Test (Cyclic Compression Test) describedabove with a 2000N maximum load, a men's size 10 midsole using thedescribed foot form for 100 cycles. EE/EI represents the averageefficiency divided by the energy intensity. An additional parameter isthe energy efficiency divided by the product of the energy intensity andthe density, EE/(EI*ρ). ER/EI represents the energy return divided bythe energy intensity. The last parameter is the energy return divided bythe product of the energy intensity and the density, EE/(EI*ρ). The dataillustrates the midsole 122 with a foam having a low density andimproved energy efficiency compared to the energy intensity. Not only isless energy required per pair, as compared to other foamed midsoles, butthe energy return and energy efficiency per energy intensity and densityis improved. The foam of the midsole 122 thus provides good energyreturn with a low density (lighter weight) midsole, while requiring lessenergy per pair to manufacture.

In Table 1, the Specimen descriptions indicate the type of outsole inthe assembly. This could be: a full outsole (Full OS), substantiallycovering the entire bottom of the midsole 122; no outsole at all (NoOS); a split midsole (Partial OS), with a portion covering the fore footarea and a portion covering the heel area; or a full outsole withlateral slits spaced along the length of the outsole (Slit OS).

TABLE 1 Representative Data-Midsole, Outsole and Strobel Energy Input(area under Foam loading Avg Max Energy Foam Avg portion of EnergyDisplace- Avg Intensity Density Effi- load-disp Returned ment Stiffness(EI) EE/ EE/ ER/ ER/ Material Specimen (ρ)[g/cc] ciency curve [mJ](ER)[mJ] [mm] [N/mm] [kW − h] EI EI * ρ EI EI * ρ Article Full OS-Left0.18 0.71 5927 4226 10.97 182 0.40 1.78 9.90 10566 58699 Foam FullOS-Right 0.18 0.72 5981 4284 10.27 195 0.40 1.79 9.95 10711 59505 (Foamof No OS-Left 0.18 0.72 6107 4380 10.77 186 0.40 1.79 9.96 10949 60827Midsole No OS-Right 0.18 0.74 5874 4327 9.99 200 0.40 1.84 10.23 1081860102 122) Partial OS-Left 0.18 0.73 5853 4251 10.46 191 0.40 1.82 10.0910627 59037 Partial OS-Right 0.18 0.74 5719 4223 9.22 217 0.40 1.8510.25 10557 58647 Slit OS-Left 0.18 0.65 6278 4065 11.53 173 0.40 1.628.99 10162 56457 Slit OS-Right 0.18 0.67 5953 4001 10.36 193 0.40 1.689.34 10003 55575 Polymeric Full OS-Left 0.2 0.76 7047 5332 10.08 1982.90 0.26 1.30 1839 9193 Foam Full OS-Right 0.2 0.76 7310 5549 10.12 1972.90 0.26 1.31 1913 9567 Composition No OS-Left 0.2 0.75 7475 5641 10.63188 2.90 0.26 1.30 1945 9727 A No OS-Right 0.2 0.75 7454 5596 10.25 1952.90 0.26 1.29 1930 9648 Partial OS-Left 0.2 0.75 6771 5092 9.81 2042.90 0.26 1.30 1756 8780 Partial OS-Right 0.2 0.76 7134 5411 9.58 2082.90 0.26 1.31 1866 9328 Slit OS-Left-cut 0.2 0.76 7159 5426 9.98 2002.90 0.26 1.31 1871 9355 Slit OS-Right 0.2 0.76 7405 5643 10.06 199 2.900.26 1.31 1946 9729 Polymeric Full OS-Left 0.22 0.72 5634.27 3920 8.18244.12 0.50 1.43 6.52 7841 35640 Foam Full OS-Right 0.22 0.68 5933.433916 8.20 243.46 0.50 1.36 6.19 7833 35603 Composition No OS-Left 0.220.70 5509.87 3724 7.67 260.33 0.50 1.39 6.33 7447 33852 B No OS-Right0.22 0.69 5782.49 3889 8.27 241.45 0.50 1.39 6.30 7777 35350 PartialOS-Left 0.22 0.70 5548.18 3787 7.90 252.66 0.50 1.41 6.40 7575 34430Partial OS-Right 0.22 0.66 5893.88 3793 8.03 248.64 0.50 1.33 6.03 758634481 Slit OS-Left-cut 0.22 0.70 5664.52 3822 7.83 255.11 0.50 1.39 6.327643 34742 Slit OS-Right 0.22 0.67 5816.88 3761 7.96 250.81 0.50 1.336.06 7522 34190

TABLE 2 Representative Data-Midsole Only Energy Input (area under Foamloading portion Energy Foam of load- Energy Avg Max Avg IntensityDensity Avg disp curve Returned Displacement Stiffness (EI) EE/ EE/ ER/ER/ Material (g/cc) Efficiency [mJ] (ER)[mJ] [mm] [N/mm] [kW − h] EIEI * ρ EI EI * ρ Article 0.18 0.77 5624 4304 10.58 189 0.40 1.93 10.6910760 59778 Foam 0.18 0.76 5744 4393 10.92 183 0.40 1.90 10.56 1098361014 (Foam of 0.18 0.78 5438 4246 10.29 194 0.40 1.95 10.83 10615 58972Midsole 0.18 0.77 5720 4419 10.49 191 0.40 1.93 10.69 11048 61375 122)0.18 0.75 5782 4321 11.17 179 0.40 1.88 10.42 10803 60014 0.18 0.77 57344400 10.65 188 0.40 1.93 10.69 11000 61111 0.18 0.77 5582 4289 10.21 1960.40 1.93 10.69 10723 59569 0.18 0.78 5641 4382 9.82 203 0.40 1.95 10.8310955 60861 0.18 0.77 5755 4442 10.15 197 0.40 1.93 10.69 11105 616940.18 0.79 5576 4378 9.68 206 0.40 1.98 10.97 10945 60806 0.18 0.76 56274271 10.51 190 0.40 1.90 10.56 10678 59319 0.18 0.78 5703 4465 9.98 2000.40 1.95 10.83 11163 62014 0.18 0.78 5680 4453 10.00 200 0.40 1.9510.83 11133 61847 0.18 0.79 5696 4494 10.07 199 0.40 1.98 10.97 1123562417 Polymeric 0.2 0.78 6964 5404 9.75 205 2.90 0.27 1.34 1863 9317Foam 0.2 0.77 6983 5375 9.70 206 2.90 0.27 1.33 1853 9267 Composition0.2 0.76 7151 5428 10.66 187 2.90 0.26 1.31 1872 9359 A 0.2 0.77 70805437 9.99 200 2.90 0.27 1.33 1875 9374 0.2 0.76 7230 5498 10.62 188 2.900.26 1.31 1896 9479 0.2 0.77 7156 5507 10.14 197 2.90 0.27 1.33 18999495 0.2 0.76 7255 5532 10.22 196 2.90 0.26 1.31 1908 9538 0.2 0.77 70425438 9.87 203 2.90 0.27 1.33 1875 9376 0.2 0.78 7438 5807 9.89 202 2.900.27 1.34 2002 10012 0.2 0.77 7766 6015 10.35 193 2.90 0.27 1.33 207410371 0.2 0.77 7624 5875 10.16 197 2.90 0.27 1.33 2026 10129 0.2 0.777739 5987 10.10 198 2.90 0.27 1.33 2064 10322 0.2 0.77 7645 5922 10.00200 2.90 0.27 1.33 2042 10210 0.2 0.77 7653 5861 10.15 197 2.90 0.271.33 2021 10105 0.2 0.77 7766 6015 10.08 198 2.90 0.27 1.33 2074 103710.2 0.77 7721 5981 10.07 198 2.90 0.27 1.33 2062 10312 Polymeric 0.220.69 7033 4878 10.11 197 0.50 1.38 6.27 9756 44345 Foam 0.22 0.69 72274983 10.69 187 0.50 1.38 6.27 9966 45300 Composition 0.22 0.69 7340 507410.89 183 0.50 1.38 6.27 10148 46127 B 0.22 0.69 7627 5255 11.03 1810.50 1.38 6.27 10510 47773 0.22 0.69 7643 5283 10.14 196 0.50 1.38 6.2710566 48027 0.22 0.69 7281 5055 9.83 203 0.50 1.38 6.27 10110 45955 0.220.69 7842 5429 10.35 192 0.50 1.38 6.27 10858 49355

TABLE 3 Representative Data-Summary Foam Energy Foam Energy IntensityDensity Return (EI) Material (ρ)[g/cc] Efficiency (ER)[mJ] [kW − h]EE/EI EE/EI * ρ ER/EI ER/(EI * ρ) Midsole Only Article Foam 0.18 0.774380 0.4 1.93 10.69 10950 60833 (Foam of Midsole 122) Polymeric Foam0.22 0.69 3950 0.5 1.38 6.27 7900 35909 Composition B Polymeric Foam0.20 0.77 5690 2.9 0.27 1.33 1962 9810 Composition A Midsole + Strobel +Outsole Article Foam 0.18 0.72 4240 0.4 1.80 10.00 10600 58889 (Foam ofMidsole 122) Polymeric Foam 0.22 0.69 3826 0.5 1.38 6.27 7652 34782Composition B ReactPolymeric 0.20 0.77 5470 2.9 0.27 1.33 1886 9431 FoamComposition A

Recyclate

With reference next to the flowchart of FIG. 20 , an improved method orcontrol strategy for manufacturing a foamed polymer article, such as themidsole 122 of FIG. 1 , is generally described at 2000 in accordancewith aspects of the present disclosure. Some or all of the operationsillustrated in FIG. 20 and described in further detail below may berepresentative of an algorithm that corresponds to processor-executableinstructions that may be stored, for example, in main or auxiliary orremote memory, and executed, for example, by a local or remotecontroller, processing unit, control logic circuit, or other module ordevice or network of devices, to perform any or all of the above orbelow described functions associated with the disclosed concepts. One ormore of the illustrated operations may be performed manually or assistedmanually by an onsite technician. It should be recognized that the orderof execution of the illustrated operation blocks may be changed,additional blocks may be added, and some of the blocks described may bemodified, combined, or eliminated.

Method 2000 of FIG. 20 is initialized at block 2001, e.g., responsive toinput of an activation command signal received from a human machineinterface (HMI) of a central control terminal. Initial stages of themanufacturing process may comprise supplying, accessing, and/orutilizing (collectively “receiving”) the various materials, tools, andmachines needed to manufacture foamed polymer articles. At process block2003, for example, a batch of recycled plastic material is accessed froman available store of polymer recyclate. As used herein, the term“recycled plastic” may encompass used or excess or scrapped plastic thatis put into a recycling stream, including wholesale recycling of entireproducts, disassembly of products and recycling only selected partsthereof, recycling of manufacturing byproduct, all of which may requiresorting and cleaning of any collected materials. For at least someembodiments, scrap and waste thermoplastic polyester elastomer (TPE-E)composition may be recovered (e.g., reclaimed from foamed or unfoamedvirgin TPE-E material and/or virgin TPE-E compositions), and thenincorporated into foamed articles produced with at least some virginTPE-E and/or virgin TPE-E compositions. The recycled TPE-E compositionmay be derived from one or more reactants, such as a poly(alkyleneoxide)diol material and/or an aromatic dicarboxylic acid material. Therecycled thermoplastic polyester elastomer composition may have a weightaverage molecular weight ranging from about 50,000 Daltons to about200,000 Daltons.

Once the batch of recycled plastic is received and any attendantsorting, cleaning, and other pre-processing is complete at process block2003, the method 2000 shreds, chops, cuts, and/or grinds (collectively“grind”) the batch of recycled plastic at process block 2005. By way ofnon-limiting example, a dedicated recycling station may be responsiblefor grinding recycled TPE-E into granular or pelletized form; groundrecycled material may be produced in real-time or stored in inventoryand reused when desired. Alternatively, “grinding” may comprise feedinga hot compound of recyclate into an extruder fitted with a perforateddie; a cutter immediately in front of the die slices extruded strings ofcompound into granulized pellets. Cut pellets are then cooled as theyare transported to a sieve grader to separate out irregularly sizedpellets. A “regrind” thermoplastic polymer composition may originatefrom re-extruded material, such as unfoamed, mold-runner derived TPE-Ecomposition waste that is put through an extruder, pelletized, andturned back into resin. Regrind may also originate from injected foammaterial, such as virgin TPE-E composition resin that is injected andfoamed during normal processing, scrapped, then shredded andre-introduced as regrind. The ground recyclate material may have anirregular shape with a major length size of about 1-10 mm, and thevirgin polymer material has a pellet size of about 1-10 mm.

At process block 2007, the ground recycled material is mixed with acomposition of virgin polymer material. As used herein, the terms“mixing” and “blending” may be used interchangeably and synonymously tomean to combine or intermingle, where the resultant mixed batch may ormay not be homogenous throughout the mixture. A recycled material may becontrasted with a virgin material in that a raw “virgin” material hasneither been injected into a mold assembly nor expanded throughactivation of an intermixed foaming agent and formed into an endproduct. The virgin polymer composition may be the same or similargeneral polymer composition as the recyclate or, alternatively, may be adistinguishable polymer composition from the recyclate. To properlycalibrate the operating parameters of the injection molding system andcontrol the functional properties of the resultant foamed polymerarticle, a metered amount of the ground recyclate material is mixed witha predetermined amount of virgin polymer material to form a mixed batchof virgin and recycled material. In at least some implementations, themetered amount is limited to about 20% by mass or less of a total massof the mixed batch. It may be desirable, depending on an intendedapplication, that about 10 to about 50 parts of recycled TPE-Ecomposition per about 80 to about 100 parts virgin TPE-E composition beincorporated into newly foamed TPE-E articles by the methods describedherein.

With continuing reference to FIG. 20 , method 2000 continues to processblock 2009 with instructions to treat the recycled material, eitherbefore, during, or after admixture with the virgin material. Processingthe recyclate may include the addition of blowing/foaming agents,fillers, pigments, and/or processing aids. In at least someimplementations, a foaming agent is incorporated as a separateingredient into the mixture of recycled and virgin polymer material forinvoking the expansion of the mixture during molding. The foaming agentmay comprise a suitable stimulant that, alone or in combination withother substances, is capable of producing a cellular structure in aplastic. Foaming agents may include fluids that expand when pressure isreleased.

It may be desirable, for at least some applications, to add a physicalfoaming agent to the mixture of recycled and virgin material during themelting of the mixture or after the mixture has melted. When injectionmolding a midsole, it may be desirable to inject a physical foamingagent into the polymer melt composition. The physical foaming agent maybe composed of one or more supercritical fluids (SCF), such assupercritical nitrogen or carbon dioxide, which is/are dissolved intothe polymer melt composition under pressure to form a single-phasesolution (SPS). As a further option, the method 2000 may becharacterized by a lack of a chemical foaming agent for the forming ofthe foamed polymer article. SCF concentration may be dictated by, amongother things, a desired solubility and a desired density. For someembodiments, a chemical blowing agent may be utilized in addition to, oras a substitute for, the physical foaming agent.

Numerous other additives may be incorporated into the recyclate batchprior to introduction into the final mold for forming the foamed polymerarticle, including fillers, activators, homogenizing agents, pigments,fire retardants, lubricants, and other suitable additives. Non-limitingexamples of filler materials include talcum powder, mica silicate,bearing sulfate, magnesium hydroxide, magnesium carbonate, magnesiumsilicate, calcium carbonate, and other commercially available fillers.The polymer compositions can also contain rubber fillers, such asethylene propylene rubber (EPR), styrene isoprene styrene (SIS)copolymer rubber, styrene butadiene rubber, as well as other polyolefinresins, in addition to ethylene-vinyl acetate (EVA) or TPE-basedmaterials. In other examples, polyethylene wax may be used as aprocessing agent, stearic acid may be used as a lubricant, dicumylperoxide may be used as a polymerization initiator, zinc oxide may beused as an activator for the foaming agent, while titanium dioxide maybe used as a white pigment or carbon black may be used as a blackpigment.

Process block 2011 of FIG. 20 includes memory-stored,processor-executable instructions to melt the ground recyclate materialand the virgin polymer material into a polymer melt composition. Itshould be appreciated that the ground recyclate and virgin polymermaterials may be separately melted and then flowed into a mixed polymermelt composition. Otherwise, the mixed batch of recyclate and virginpolymer materials produced at process block 2007 may be heated into thepolymer melt composition. For at least some embodiments, the mixture ofground recyclate and virgin polymer materials has a set pointtemperature ranging from about 190° C. to about 215° C. Moreover, themixed batch of the ground recyclate material and the virgin polymermaterial may have an average peak crystallization temperature rangingfrom about 135° C. to about 165° C.

Once the polymer composition is complete and ready for molding, theprocessed recycled and virgin material is pressurized andinjected—colloquially “shot”—into the internal cavity or cavities of amold assembly to form the foamed polymer article, as indicated atprocess block 2013. After the SCF is injected into the polymer meltcomposition, where the SCF dissolves in the melt to form a molten SPS,the molten SPS is flowed into the internal mold cavities. The SCF isemployed as a physical blowing agent to expand the melted TPE-Ecomposition and thereby fill the mold cavities. The pressure within themold cavities is reduced or eliminated to release the SCF from the SPS,and the expanded melt is allowed to cool and solidify. To provide a“closed loop” molding system with circular sustainability thateliminates most if not all manufacturing scrap and waste, the mass ofrecycled thermoplastic resin within the internal mold cavities may begreater than or equal to a mass of the mixed thermoplastic resin withinany filling portions fluidly coupled to the cavities.

To ensure the integrity and desired performance characteristics of theresultant foamed polymer article, one or more operating parameters ofthe injection molding system may be modulated to accommodate the percentmass of recyclate being incorporated into the polymer mixes. Forinstance, the injection molding system may be set to a molding melttemperature of between about 210° C. and about 215° C. with a batch melttemperature of approximately 190° C. and a crystallization temperatureof approximately 147° C. In addition to the selective control of moldtemperatures, gas counter-pressure release rates and hold times may berecalibrated to a TPE-E polymer melt composition with approximately 20%by mass recycled TPE-E composition, e.g., to regulate cooling rateswithin the mold cavities (e.g., higher pressure drop provides fastercooling rate with less cooling time). System operating parameters may beselectively modified to ensure that the polymer melt composition stayswithin a pre-calculated melt temp-crystallization temp sweet spot for aselected timeframe within the processing cycle.

The foamed polymer article is ejected from the internal mold cavity atprocess block 2015. For at least some embodiments, the formed foamedpolymer article has a cell size average, e.g., by volume of a longestcell dimension, of less than about 0.68 mm or, in some embodiments,about 0.18 mm to about 0.58 mm. For at least some implementations, thefoamed polymer article may exhibit some and/or all of the followingcharacteristics: (1) an energy efficiency of about 55% to about 95% or,in some preferred configurations, a target efficiency of 70% to 85%; (2)an energy return of about 1000 millijoules (mJ) to about 7000 mJ or, insome preferred configurations, a target return of 4500 mJ to 5500 mJ(e.g., assuming a standard midsole geometry); and/or (3) a density ofabout 0.15 grams/cubic centimeter (g/cc) to about 0.25 g/cc or, in somepreferred configurations, a target density of 0.18 g/cc to 0.20 g/cc.

As yet a further option, a formed foamed polymer article may exhibit aratio of energy efficiency to energy intensity (EE/EI) that is greaterthan about 1.125 or, for some embodiments, greater than about 1.35 or,for some desired embodiments, greater than about 1.5 or, optionally,between about 1.6 and 2.1. Likewise, a formed foamed polymer article mayexhibit a ratio of energy efficiency to the product of energy intensityand density (EE/(EI*ρ)) that is greater than about 5.25 or, for someembodiments, greater than about 6.3 or, for some desired embodiments,greater than about 7.0 or, optionally, between about 8.8 and 11.2.Moreover, a formed foamed polymer article may exhibit a ratio of energyreturn to energy intensity (ER/EI) that is greater than about 6,375 or,for some embodiments, greater than about 7,650 or, for some desiredembodiments, greater than about 8,500 or, optionally, between about9,900 and 11,300. A formed foamed polymer article may exhibit a ratio ofenergy return to the product of energy intensity and density (ER/(EI*ρ))that is greater than about 33,750 or, for some embodiments, greater thanabout 40,500 or, for some desired embodiments, greater than about 45,000or, optionally, between about 55,400 and 62,500.

For at least some embodiments, a foamed polymer sole componentfabricated from both recyclate and virgin thermoplastic materials mayhave an energy return measurement that is within a predefined toleranceof an energy return measurement of a comparable shoe sole componentformed solely from virgin thermoplastic materials. This predefinedtolerance may be about 75% to about 99% of the energy return measurementof the comparable shoe sole component. The foamed sole component and thecomparable shoe sole component may share a comparable shape, size,and/or method of molding. At this juncture, the method 2000 mayterminate or may loop back to block 2001 and run in a repeatable orcontinuous loop.

It is envisioned that disclosed manufacturing systems and processes mayutilize any logically relevant source of recycled plastic material inorder to conserve natural resources, minimize use of raw materials, anddivert waste from landfills with the aspiration of reaching a “circulareconomy”. In this regard, aspects of this disclosure are directed to“closed-loop” manufacturing processes that limit usable recyclatesources to manufacturing byproducts (e.g., gate or runner trimmings) andreground defective articles (e.g., visually or mechanically flawedfoamed polymer footwear sole elements). Implementing such “closed-loop”manufacturing processes may desirably optimize material use efficienciesby achieving, for example, a zero-waste or near-zero-waste of polymermaterials in the manufacture of foamed polymer articles.

As an extension of, a modification to, or a standalone process from themethod 2000 of FIG. 20 , a method of producing foamed polymer articlesmay be composed of a series of controlled manufacturing steps, includingexecuting one or more production runs to form one or more types offoamed polymer articles. A “production run” may be typified by apredefined number of articles (e.g., 220-260 articles/hr) of adesignated design/model (e.g., NIKE® REACT FLYKNIT™) having a presetshape, size and material composition (e.g., single-piece TPE-E midsolefor women's size 7 running shoe) produced substantially contiguously bya particular production line. Individual runs may exhibit differentquantifiable production variables, including: an average article massm_(AA) of the foamed polymer articles (e.g., average total mass of allarticles per run or average individual article mass or all articles perrun), and an average article defect rate DA (e.g., ratio of totaldefective articles to total articles produced per run). Because theprocess may produce multiple envelopes of products, e.g.,distinguishable from each other in quantity and geometry, the toolingfor each geometry may consume a distinct volume of raw materials andgenerate a distinct volume of manufacturing byproduct.

As will be explained in further detail below, a production line maygenerate a baseline average byproduct value (e.g., unfoamed byproductgenerated upstream of tooling and/or foamed byproduct generateddownstream of tooling). For a particular production run, an averagebyproduct mass amount may be calculated as the sum of: (1) an amount ofbyproduct generated for each geometry produced in a run divided by thequantity of each geometry in the run; and (2) a remnant upstreambyproduct mass per run. By way of non-limiting example, a run size for aproduction run may include 100 total articles, including twenty of afirst geometry, twenty of a second geometry, and sixty of a thirdgeometry. In this instance, byproduct mass may be calculated as: (totalbyproduct mass for first geometry)/20+(total byproduct mass fir secondgeometry)/20+(total byproduct mass for third geometry)/60+upstreamand/or downstream byproduct mass.

For at least some implementations, a production run may be limited to asingle run for fabricating a preset number of a singular article designhaving a predefined shape and size. Alternatively, a mass production runmay include multiple batch runs of different types of polymer articles,with each type having a respective shape and size. These batchproduction runs may be performed simultaneously or sequentially, witheach run producing the same number of articles or a distinct number ofarticles. When carrying out multiple batch runs as part of a larger massproduction run, the average article mass m_(AA) for the mass run may becalculated as the arithmetic sum of the individual average articlemasses for all of the discrete runs, namely: m_(AA−1)+m_(AA−2)+ . . .+m_(AA−n). Likewise, the average article defect rate {dot over (D)}_(A)for the mass run may be calculated as the arithmetic mean of theindividual average article defect rates for all of the discrete batchruns, namely: ({dot over (D)}_(A-1)+{dot over (D)}_(A-2)+ . . . +{dotover (D)}_(A-n))/n.

After completing a single production run or a group of discretized batchruns of foamed polymer articles, the method may include reclaiming andrecycling one or more batches of manufacturing byproduct incidental tothe run or runs. Recyclate byproduct material may be recovered fromsections of the molding system upstream from the mold tool (e.g., fromhot-runner or cold runner plates), downstream from the mold tool (e.g.,mold flash and trimmings), and/or from within the mold tool itself(e.g., inlet and outlet gates to the mold-ring cavities). In thisexample, the manufacturing byproduct may have an average byproduct massm_(AB) (e.g., average total byproduct mass per run or average byproductmass per article per run). When carrying out multiple batch runs, theaverage byproduct mass for the entire mass production run may becalculated as the arithmetic sum of the individual average byproductmasses, namely: m_(AB−1)+m_(AB−2)+ . . . +m_(AB−n). Alternatively, theaverage byproduct mass may be calculated as the arithmetic sum of: (1) afirst byproduct mass incidental to a first batch run divided by a firstnumber of first polymer articles in that run; (2) a second byproductmass incidental to a second batch run divided by a second number ofsecond polymer articles in that run; . . . and (n) an n^(th) byproductmass incidental to an n^(th) batch run divided by an n^(th) number ofpolymer articles in that run.

Prior to, contemporaneous with, or after retrieving the batch ofmanufacturing byproducts, the method may also include reclaiming andrecycling one or more lots of defective articles incidental to theproduction run(s). In accord with the abovementioned footwear example,recycled defect material may be recovered from pre-consumer footwearand, if desired, from post-consumer footwear. For pre-consumer products,a defective foamed article may be identified through any commerciallyavailable technique for identifying manufacturing defects. For instance,the injection molding system may incorporate a system-automated visualinspection station and a system-automated mechanical testing stationdownstream from the tooling assembly of FIG. 17 or 19 . The visualinspection station may utilize a high-definition digital camera and amachine-learning algorithm to search for and flag any of a multitude ofpredefined visual defects (e.g., dimensional flaws, superficialblemishes, contour defects, etc.). Moreover, the mechanical testingstation may be in the nature of an impact-testing machine with a linearforce transducer operatively coupled to a motor-driven, last-shapedplunger. The plunger and transducer collectively measure each foamarticle's stiffness, energy efficiency, energy return, etc., and flagthe article as defective if any of these measurements fall outside ofcorresponding manufacturing tolerance ranges.

Continuing the discussion of pre-consumer defective products, there willbe an associated average defect mass m_(AD) (per run) in themanufacturing system. This average defect mass m_(AD) may be calculatedas the arithmetic product of the article defect rate DA and the averagearticle mass m_(AA), or m_(AD) {dot over (D)}_(A)*m_(AA). Forimplementations that execute multiple batch runs as part of a largermass production run, the average defect mass m_(AD) may be thearithmetic mean of the individual average defect masses incidental tothe various production runs, namely: (m_(AD−1)+m_(AD−2)+ . . .+m_(AD−n))/n. To achieve a “closed-loop” manufacturing process, thesystem may be restricted as follows:

(m _(AB) +m _(AD))/m _(AA)≤0.2

During a closed-loop manufacturing process, foam polymer waste—themanufacturing byproducts and defective articles—may be added directlyinto the injection barrel for subsequent injection into the mold toolcavity. The foam polymer waste may be crushed or shredded, mixed withvirgin pellets, and fed together into the same injection barrel. In thisinstance, a power-screw type “crammer” feeder may be used to force thewaste material back into the tooling assembly. Prior to re-feeding thematerial, the foam polymer waste may be shredded at least once or, in atleast some applications, two or more times to ensure that thediscretized waste elements are generally uniform in shape and size. Ifit determined that the foam polymer waste cannot be added directly tothe injection barrel, the foam waste may need to be processed, melteddown, and re-pelletized. In this case, the waste material would beshredded a single time or multiple times, fed into a separate extrusionline where it is melted and extruded, and thereafter pelletized to formpellets akin in geometry and density to virgin pellets. These “new”waste material pellets may then be combined with virgin pellets in theinjection barrel.

An injection molding system's operating parameters will potentiallychange depending on the type and volume of recyclate being used to formthe foamed polymer articles. For instance, the melt temperatures willlikely be modified to successfully process recycled material: whenfoamed, the recyclate material's crystallization temperature mayincrease (i.e., crystallization temperature gets closer to the melttemperature). As such, the melt composition may need to be processed athigher temperatures compared to processing temperatures that wouldtypically be used for pure virgin material. For at least some footwearmidsole embodiments, the production variables per run may be based onthe following parameters: about 0.2 kg/pair, about two pair (fourmidsoles)/minute, eight hour shift, about 10% to about 15% runner wasterelative to midsole weight per pair.

Aspects of this disclosure may be implemented, in some embodiments,through a computer-executable program of instructions, such as programmodules, generally referred to as software applications or applicationprograms executed by any of a controller or the controller variationsdescribed herein. Software may include, in non-limiting examples,routines, programs, objects, components, and data structures thatperform particular tasks or implement particular data types. Thesoftware may form an interface to allow a computer to react according toa source of input. The software may also cooperate with other codesegments to initiate a variety of tasks in response to data received inconjunction with the source of the received data. The software may bestored on any of a variety of memory media, such as CD-ROM, magneticdisk, and semiconductor memory (e.g., various types of RAM or ROM).

Moreover, aspects of the present disclosure may be practiced with avariety of computer-system and computer-network configurations,including multiprocessor systems, microprocessor-based orprogrammable-consumer electronics, minicomputers, mainframe computers,and the like. In addition, aspects of the present disclosure may bepracticed in distributed-computing environments where tasks areperformed by resident and remote-processing devices that are linkedthrough a communications network. In a distributed-computingenvironment, program modules may be located in both local and remotecomputer-storage media including memory storage devices. Aspects of thepresent disclosure may therefore be implemented in connection withvarious hardware, software or a combination thereof, in a computersystem or other processing system.

Any of the methods described herein may include machine readableinstructions for execution by: (a) a processor, (b) a controller, and/or(c) any other suitable processing device. Any algorithm, software,control logic, protocol or method disclosed herein may be embodied assoftware stored on a tangible medium such as, for example, a flashmemory, a solid-state memory, a CD-ROM, a hard drive, a digitalversatile disk (DVD), or other memory devices. The entire algorithm,control logic, protocol, or method, and/or parts thereof, mayalternatively be executed by a device other than a controller and/orembodied in firmware or dedicated hardware in an available manner (e.g.,implemented by an application specific integrated circuit (ASIC), aprogrammable logic device (PLD), a field programmable logic device(FPLD), discrete logic, etc.). Further, although specific algorithms aredescribed with reference to flowcharts depicted herein, many othermethods for implementing the example machine-readable instructions mayalternatively be used.

The present invention has been described in relation to particularexamples, which are intended in all respects to be illustrative ratherthan restrictive. From the foregoing, it will be seen that thisinvention is one well adapted to attain all the ends and objects setforth above, together with other advantages which are obvious andinherent to the system and method. It will be understood that certainfeatures and subcombinations are of utility and may be employed withoutreference to other features and subcombinations. This is contemplated byand is within the scope of the claims.

Some aspects of this disclosure have been described with respect to theexamples provided in the FIGURES. Additional aspects of the disclosurewill now be described that may be related subject matter included in oneor more claims or clauses of this application at the time of filing, orone or more related applications, but the claims or clauses are notlimited to only the subject matter described in the below portions ofthis description. These additional aspects may include featuresillustrated by the FIGURES, features not illustrated by the FIGURES, andany combination thereof. When describing these additional aspects,reference may be made to elements depicted by the FIGURES forillustrative purposes.

As used herein and in connection with the claims listed hereinafter, theterminology “any of clauses” or similar variations of said terminologyis intended to be interpreted such that features of claims/clauses maybe combined in any combination. For example, an exemplary clause 4 mayindicate the method/apparatus of any of clauses 1 through 3, which isintended to be interpreted such that features of clause 1 and clause 4may be combined, elements of clause 2 and clause 4 may be combined,elements of clause 3 and 4 may be combined, elements of clauses 1, 2,and 4 may be combined, elements of clauses 2, 3, and 4 may be combined,elements of clauses 1, 2, 3, and 4 may be combined, and/or othervariations.

The following clauses are aspects contemplated herein.

Clause 1. A thermoplastic elastomeric composition comprising: athermoplastic elastomeric foam comprising, a plurality of firstsegments, each first segment derived from a dihydroxy-terminatedpolydiol; a plurality of second segments, each second segment derivedfrom a diol; and a plurality of third segments, each third segmentderived from an aromatic dicarboxylic acid.

Clause 2. The thermoplastic elastomeric composition of clause 1, whereinthe thermoplastic elastomeric foam is a block copolymer; a segmentedcopolymer; a random copolymer; or a condensation copolymer.

Clause 3. The thermoplastic elastomeric composition of clauses 1 or 2,wherein the thermoplastic elastomeric foam has a weight averagemolecular weight of about 50,000 Daltons to about 1,000,000 Daltons.

Clause 4. The thermoplastic elastomeric composition of clause 3, whereinthe thermoplastic elastomeric foam has a weight average molecular weightof about 50,000 Daltons to about 500,000 Daltons; about 75,000 Daltonsto about 300,000 Daltons; or about 100,000 Daltons to about 200,000Daltons.

Clause 5. The thermoplastic elastomeric composition of any one ofclauses 1-4, wherein the thermoplastic elastomeric foam has a ratio offirst segments to third segments from about 1:1 to about 1:5 based onthe weight of each of the first segments and the third segments.

Clause 6. The thermoplastic elastomeric composition of clause 5, whereinthe thermoplastic elastomeric foam has a ratio of first segments tothird segments from about 1:1 to about 1:3 or about 1:1 to about 1:2based on the weight of each of the first segments and the thirdsegments.

Clause 7. The thermoplastic elastomeric composition of any one ofclauses 1-6, wherein the thermoplastic elastomeric foam has a ratio ofsecond segments to third segments from about 1:1 to about 1:3 based onthe weight of each of the first segments and the third segments.

Clause 8. The thermoplastic elastomeric composition clause 7, whereinthe thermoplastic elastomeric foam has a ratio of second segments tothird segments from about 1:1 to about 1:2 or about 1:1 to about 1:1.52based on the weight of each of the first segments and the thirdsegments.

Clause 9. The thermoplastic elastomeric composition of any one ofclauses 1-8, wherein the first segments derived from adihydroxy-terminated polydiol comprise segments derived from apoly(alkylene oxide)diol having a number-average molecular weight ofabout 250 Daltons to about 6000 Daltons.

Clause 10. The thermoplastic elastomeric composition of clause 9,wherein the number-average molecular weight is about 400 Daltons toabout 6,000 Daltons; about 350 Daltons to about 5,000 Daltons; or about500 Daltons to about 3,000 Daltons.

Clause 11. The thermoplastic elastomeric composition of any one ofclauses 9-10, wherein the poly(alkylene oxide)diol is poly(ethyleneether)diol; poly(propylene ether)diol; poly(tetramethylene ether)diol;poly(pentamethylene ether)diol; poly(hexamethylene ether)diol;poly(heptamethylene ether)diol; poly(octamethylene ether)diol;poly(nonamethylene ether)diol; poly(decamethylene ether)diol; ormixtures thereof.

Clause 12. The thermoplastic elastomeric composition of clause 11,wherein the poly(alkylene oxide)diol is poly(ethylene ether)diol;poly(propylene ether)diol; poly(tetramethylene ether)diol;poly(pentamethylene ether)diol; or poly(hexamethylene ether)diol.

Clause 13. The thermoplastic elastomeric composition of clause 11,wherein the poly(alkylene oxide)diol is poly(tetramethylene ether)diol.

Clause 14. The thermoplastic elastomeric composition of any one ofclauses 1-13, wherein the second segments derived from a diol comprise adiol having a molecular weight of less than about 250.

Clause 15. The thermoplastic elastomeric composition of clause 14,wherein the diol is a C2-C8 diol.

Clause 16. The thermoplastic elastomeric composition of clause 15,wherein the second segments derived from a diol comprise a diol selectedfrom ethanediol; propanediol; butanediol; pentanediol; 2-methylpropanediol; 2,2-dimethyl propanediol; hexanediol; 1,2-dihydroxycyclohexane; 1,3-dihydroxy cyclohexane; 1,4-dihydroxy cyclohexane; andmixtures thereof.

Clause 17. The thermoplastic elastomeric composition of clause 16,wherein the diol is selected from 1,2-ethanediol, 1,3-propanediol,1,4-butanediol, 1,6-hexanediol, and mixtures thereof.

Clause 18. The thermoplastic elastomeric composition of any one ofclauses 1-17, wherein the third segments derived from an aromaticdicarboxylic acid comprise an aromatic C5-C16 dicarboxylic acid.

Clause 19. The thermoplastic elastomeric composition of clause 18,wherein the aromatic C5-C16 dicarboxylic acid has a molecular weightless than about 300 Daltons or about 120 Daltons to about 200 Daltons.

Clause 20. The thermoplastic elastomeric composition of clause 18,wherein the aromatic C5-C16 dicarboxylic acid is terephthalic acid,phthalic acid, isophthalic acid, or a derivative thereof.

Clause 21. The thermoplastic elastomeric composition of clause 20,wherein the aromatic C5-C16 dicarboxylic acid is terephthalic acid orthe dimethyl ester derivative thereof.

Clause 22. The thermoplastic elastomeric composition of any one ofclauses 1-21, wherein the thermoplastic elastomeric foam comprises, aplurality of first copolyester units, each first copolyester unit of theplurality comprising the first segment derived from adihydroxy-terminated polydiol and the third segment derived from anaromatic dicarboxylic acid, wherein the first copolyester unit has astructure represented by a formula 1:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide)diol of the first segment, whereinthe poly(alkylene oxide)diol of the first segment is a poly(alkyleneoxide)diol having a number-average molecular weight of about 400 toabout 6000;and wherein R₂ is a group remaining after removal of carboxyl groupsfrom the aromatic dicarboxylic acid of the third segment; and aplurality of second copolyester units, each second copolyester unit ofthe plurality comprising the second segment derived from a diol and thethird segment derived from an aromatic dicarboxylic acid, wherein thesecond copolyester unit has a structure represented by a formula 2:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

Clause 23. The thermoplastic elastomeric composition of clause 22,wherein the first copolyester unit has a structure represented by aformula 3:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons.

Clause 24. The thermoplastic elastomeric composition of clause 23,wherein y is an integer having a value of 1, 2, 3, 4, or 5.

Clause 25. The thermoplastic elastomeric composition of clause 23 or 24,wherein R is hydrogen; wherein R is methyl; wherein R is hydrogen and yis an integer having a value of 1, 2, or 3; or wherein R is methyl and yis an integer having a value of 1.

Clause 26. The thermoplastic elastomeric composition of clause 22,wherein the first copolyester unit has a structure represented by aformula 4:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons.

Clause 27. The thermoplastic elastomeric composition of any one ofclauses 23-26, wherein z is an integer having a value from 5 to 60; from5 to 50; from 5 to 40; from 4 to 30; from 4 to 20; or from 2 to 10.

Clause 28. The thermoplastic elastomeric composition of any one ofclauses 23-27, wherein the weight average molecular weight of each ofthe plurality of first copolyester units is from about 400 Daltons toabout 6,000 Daltons; from about 400 Daltons to about 5,000 Daltons; fromabout 400 Daltons to about 4,000 Daltons; from about 400 Daltons toabout 3,000 Daltons; from about 500 Daltons to about 6,000 Daltons; fromabout 500 Daltons to about 5,000 Daltons; from about 500 Daltons toabout 4,000 Daltons; from about 500 Daltons to about 3,000 Daltons; fromabout 600 Daltons to about 6,000 Daltons; from about 600 Daltons toabout 5,000 Daltons; from about 600 Daltons to about 4,000 Daltons; fromabout 600 Daltons to about 3,000 Daltons.

Clause 29. The thermoplastic elastomeric composition of any one ofclauses 22-28, wherein the second copolyester unit has a structurerepresented by a formula 5:

wherein x is an integer having a value from 1 to 20.

Clause 30. The thermoplastic elastomeric composition of clause 29,wherein x is an integer having a value from 2 to 18; a value from 2 to17; a value from 2 to 16; a value from 2 to 15; a value from 2 to 14; avalue from 2 to 13; a value from 2 to 12; a value from 2 to 11; a valuefrom 2 to 10; a value from 2 to 9; a value from 2 to 8; a value from 2to 7; a value from 2 to 6; or a value of 2, 3, or 4.

Clause 31. The thermoplastic elastomeric composition of clause 29,wherein the second copolyester unit has a structure represented by aformula 6:

Clause 32. The thermoplastic elastomeric composition of any one ofclauses 22-31, wherein the thermoplastic elastomeric foam comprises aweight percent of the plurality of first copolyester units based ontotal weight of the thermoplastic elastomeric foam of about 30 weightpercent to about 80 weight; about 40 weight percent to about 80 weightpercent; about 50 weight percent to about 80 weight percent; about 30weight percent to about 70 weight percent; about 40 weight percent toabout 70 weight percent; or about 50 weight percent to about 70 weightpercent.

Clause 33. The thermoplastic elastomeric composition of any one ofclauses 22-32, wherein the thermoplastic elastomeric foam comprises aweight percent of the plurality of second copolyester units based ontotal weight of the thermoplastic elastomeric foam of about 40 weightpercent to about 65 weight percent; about 45 weight percent to about 65weight percent; about 50 weight percent to about 65 weight percent;about 55 weight percent to about 65 weight percent; about 40 weightpercent to about 60 weight percent; about 45 weight percent to about 60weight percent; about 50 weight percent to about 60 weight percent; orabout 55 weight percent to about 60 weight percent.

Clause 34. The thermoplastic elastomeric composition of any one ofclauses 1-33, wherein the thermoplastic elastomeric composition furthercomprises an additive.

Clause 35. The thermoplastic elastomeric composition of clause 34,wherein the additive is present in an amount from about 0.1 weightpercent to about 10 weight percent based on the total weight of thefoamed polymeric material.

Clause 36. The thermoplastic elastomeric composition of clauses 34 or35, wherein the additive is a wax, an anti-oxidant, a UV-absorbingagent, a coloring agent, or combinations thereof.

Clause 37. The thermoplastic elastomeric composition of any one ofclauses 1-36, wherein the thermoplastic elastomeric composition furthercomprises a filler.

Clause 38. The thermoplastic elastomeric composition of clause 37,wherein the filler is present in an amount from about 0.05 weightpercent to about 20 weight percent or from about 0.1 weight percent toabout 10 weight percent based on the total weight of the foamedpolymeric material.

Clause 39. The thermoplastic elastomeric composition of any one ofclause 37 or 38, wherein the filler is a particulate filler; or whereinthe filler is a carbonaceous filler.

Clause 40. The thermoplastic elastomeric composition of clause 39,wherein the carbonaceous filler is carbon black, activated carbon,graphite, carbon fibers, carbon fibrils, carbon nanoparticles, orcombinations thereof; and wherein the carbonaceous filler is optionallychemically-modified.

Clause 41. The thermoplastic elastomeric composition of clause 37,wherein the filler is an inorganic filler.

Clause 42. The thermoplastic elastomeric composition of clause 41,wherein the inorganic filler is an oxide, a hydroxide, a salt, asilicate, a metal, or combinations thereof; or wherein the inorganicfiller comprises glass spheres, glass fibers, glass hollow spheres,glass flakes, MgO, SiO₂, Sb₂O₃, Al₂O₃, ZnO, talc, mica, kaolin,wollastonite, or combinations thereof.

Clause 43. The thermoplastic elastomeric composition of any one ofclauses 37-41, wherein the filler is present in an amount for from about0.1 weight percent to less than about 15 weight percent.

Clause 44. The thermoplastic elastomeric composition of clause 43,wherein the filler is present in an amount for from about 0.1 weightpercent to about 10 weight percent.

Clause 45. The thermoplastic elastomeric composition of clause 43,wherein the filler is present in an amount for from about 0.1 weightpercent to about 7.5 weight percent.

Clause 46. The thermoplastic elastomeric composition of clause 43,wherein the filler is present in an amount for from about 0.1 weightpercent to about 5 weight percent.

Clause 47. The thermoplastic elastomeric composition of clause 43,wherein the filler is present in an amount for from about 0.1 weightpercent to about 4 weight percent.

Clause 48. The thermoplastic elastomeric composition of any one ofclauses 1-47, wherein the thermoplastic elastomeric composition consistsessentially of one or more thermoplastic copolyester.

Clause 49. The thermoplastic elastomeric composition of any one ofclauses 1-48, further comprising at least one ionomer.

Clause 50. The thermoplastic elastomeric composition of any one ofclauses 1-48, further comprising at least one thermoplasticpolyurethane.

Clause 51. The thermoplastic elastomeric composition of any one ofclauses 1-50, wherein the thermoplastic elastomeric composition issubstantially free of a thermoplastic polyamide polymer, includepolyamide copolymers such as polyether block amide copolymers.

Clause 52. The thermoplastic elastomeric composition of any one ofclauses 1-50, wherein the thermoplastic elastomeric composition issubstantially free of a thermoplastic polyolefin polymers, includingpolyethylene and polypropylene and/or polyolefin copolymers such asethylene-vinyl acetate copolymers.

Clause 53. The thermoplastic elastomeric composition of any one ofclauses 1-52, wherein thermoplastic copolyester has a zero shearviscosity when determined using a flow curve obtained on a rotationalrheometer as described herein of about 10 to about 10,000 pascal-second;about 100 to about 7,000 pascal-second; or about 1,000 to about 5,000pascal-second.

Clause 54. A foam article, comprising: a foamed component, the componentcomprises a foam volume, the foam volume comprises a plurality of foamsub-volumes, with one injection gate vestige for each of the pluralityof foam sub-volumes, wherein each foam sub-volume of the plurality offoam sub-volumes has a corresponding aspect ratio and wherein the aspectratio of each foam sub-volume of the plurality of foam sub-volumes isgreater than 2.7.

Clause 55. The foam article of clause 54, wherein the aspect ratio ofeach foam sub-volume is greater than 3.0.

Clause 56. The foam article of clause 54, wherein the aspect ratio ofeach foam sub-volume is greater than 3.5.

Clause 57. The foam article of clause 54, wherein the componentcomprises a thermoplastic elastomeric foam having a multicellularstructure.

Clause 58. The foam article of clause 57, wherein the thermoplasticelastomeric foam is the product of foaming a thermoplastic elastomericcomposition using a physical foaming agent.

Clause 59. The foam article of clause 54, wherein the article is amidsole that has at least six foam sub-volumes.

Clause 60. The foam article of clause 59, wherein the midsole comprisesa gate vestige axis extending between a first gate vestige of theplurality of gate vestiges and a second gate vestige of the plurality ofgate vestiges, and wherein at least a third gate vestige is offset fromthe gate vestige axis.

Clause 61. The foam article of clause 60, further comprising at least afourth gate vestige that is offset from the gate vestige axis.

Clause 62. The foam article of clause 61, wherein a line extendingbetween the third gate vestige and the fourth gate vestige is orthogonalto the gate vestige axis.

Clause 63. The foam article of clause 61, wherein the midsole comprisesa toe area, a mid-foot area and a heel area, and wherein the third gatevestige and the fourth gate vestige are in the heel area.

Clause 64. The foam article of clause 58, wherein the thermoplasticelastomeric foam comprises at least one thermoplastic polyester,comprises less than 5 weight percent of a non-polymeric componentincluding a filler, or a nucleating agent, or a pigment, or a chemicalfoaming agent, or a crosslinking agent, or any combination thereof.

Clause 65. The foam article of clause 57, wherein the multicellular foamstructure is an open-cell structure.

Clause 66. The foam article of clause 57, wherein the multicellular foamstructure is a closed-cell structure.

Clause 67. The foam article according to any one of clauses 54-66,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 68. A foam article, comprising: a foamed component, the componentcomprising a foam volume, the foam volume comprises a plurality of foamsub-volumes each having one gate vestige of a plurality of gatevestiges, the component further comprising a gate vestige axis extendingbetween a first gate vestige of the plurality of gate vestiges and asecond gate vestige of the plurality of gate vestiges, wherein at leasta third gate vestige of the plurality of gate vestiges is offset fromthe gate vestige axis.

Clause 69. The foam article of clause 68, wherein the componentcomprises a thermoplastic elastomeric foam having a multicellularstructure.

Clause 70. The foam article of clause 69, wherein the thermoplasticelastomeric foam is the product of foaming a thermoplastic elastomericcomposition using a physical foaming agent.

Clause 71. The foam article of clause 70, wherein the thermoplasticelastomeric composition comprises at least one thermoplasticcopolyester, comprises less than 5 weight percent of a non-polymericcomponent including a filler, or a nucleating agent, or a pigment, or achemical foaming agent, or a crosslinking agent, or any combinationthereof.

Clause 72. The foam article of clause 69, wherein the multicellular foamstructure is an open-cell structure.

Clause 73. The foam article of clause 69, wherein the multicellular foamstructure is a closed-cell structure.

Clause 74. The foam article of clause 68, wherein the article is acushioning element in the form of a midsole for an article of footwear.

Clause 75. The foam article of clause 74, wherein the midsole has alongitudinal axis, and wherein the gate vestige axis aligns with thelongitudinal axis.

Clause 76. The foam article of clause 75, further comprising at least afourth gate vestige that is offset from the gate vestige axis.

Clause 77. The foam article of clause 76, wherein a line extendingbetween the third gate vestige and the fourth gate vestige is orthogonalto the gate vestige axis.

Clause 78. The foam article of clause 77, wherein the midsole comprisesa toe area, a mid-foot area and a heel area, and wherein the third gatevestige and the fourth gate vestige are in the heel area.

Clause 79. The foam article according to any one of clauses 68-78,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 80. A foam article, comprising: a foam component, the componentcomprising a foam volume, the article foam volume comprises a pluralityof foam sub-volumes, the component further comprising one injection gatevestige at an outward-facing surface of each foam sub-volume, wherein aplurality of ridges on the outward-facing surface extend concentricallyoutwardly from an injection gate vestige of at least one of theplurality of foam sub-volumes.

Clause 81. The foam article of clause 80, wherein the componentcomprises a thermoplastic elastomeric foam having a multicellularstructure.

Clause 82. The foam article of clause 81, wherein the thermoplasticelastomeric foam is the product of foaming a thermoplastic elastomericcomposition using a physical foaming agent.

Clause 83. The foam article of clause 82, wherein the thermoplasticelastomeric composition comprises at least one thermoplastic polyester,comprises less than 5 weight percent of a non-polymeric componentincluding a filler, or a nucleating agent, or a pigment, or a chemicalfoaming agent, or a crosslinking agent, or any combination thereof.

Clause 84. The foam article of clause 83, wherein the multicellular foamstructure is an open-cell structure.

Clause 85. The foam article of clause 82, wherein the multicellular foamstructure is a closed-cell structure.

Clause 86. The foam article of clause 80, wherein the foam article is acushioning element in the form of a midsole for an article of footwear.

Clause 87. The foam article of clause 82, wherein at least some of theplurality of ridges on the outward-facing surface extend concentricallyoutwardly from an injection gate vestige to form a series of concentriccircles.

Clause 88. The foam article of clause 87, wherein a first plurality ofridges forming a series of concentric circles extend from a firstinjection gate vestige, and a second plurality of ridges forming aseries of concentric circles extend from a second injection gatevestige.

Clause 89. The foam article of clause 88, wherein the series ofconcentric circles extend farther concentrically from the firstinjection gate vestige than the second injection gate vestige.

Clause 90. The foam article of clause 87, wherein the series ofconcentric circles extend at least 10 millimeters from a respectiveinjection gate vestige.

Clause 91. The foam article of clause 87, wherein the series ofconcentric circles extend at least 20 millimeters from a respectiveinjection gate vestige.

Clause 92. The foam article of clause 87, wherein the series ofconcentric circles extend at least 30 millimeters from a respectiveinjection gate vestige.

Clause 93. The foam article according to any one of clauses 80-92,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 94. A foam article, comprising: a foam component, the componentcomprising a foam volume comprising a foam core and a surface skinsurrounding the foam core, the skin having a profile defined by an outerside wall, the skin having a top surface and a bottom surface, and anouter perimeter edge at the intersection of the outer side wall and thetop surface, the top surface having a plurality of striation bandsextending outwardly from an inner portion of the component to the outerperimeter.

Clause 95. The foam article of clause 94, wherein the componentcomprises a thermoplastic elastomeric foam having a multicellularstructure.

Clause 96. The foam article of clause 95, wherein the thermoplasticelastomeric foam is the product of foaming a thermoplastic elastomericcomposition using a physical foaming agent.

Clause 97. The foam article of clause 96, wherein the thermoplasticelastomeric composition comprises at least one thermoplastic polyester,comprises less than 5 weight percent of a non-polymeric componentincluding a filler, or a nucleating agent, or a pigment, or a chemicalfoaming agent, or a crosslinking agent, or any combination thereof.

Clause 98. The foam article of clause 97, wherein the multicellular foamstructure is an open-cell structure.

Clause 99. The foam article of clause 97, wherein the multicellular foamstructure is a closed-cell structure.

Clause 100. The foam article of clause 94, wherein the foam article is acushioning element in the form of a midsole for an article of footwear.

Clause 101. The foam article of clause 100, wherein foam volumecomprises a plurality of foam sub-volumes, and wherein at least some ofthe plurality of striation bands extend in at least two of the pluralityof foam sub-volumes.

Clause 102. The foam article of clause 100, wherein each of theplurality of foam sub-volumes has a corresponding injection gatevestige, and wherein at least some of the plurality of striation bandsextend radially toward at least one injection gate vestige.

Clause 103. The foam article of clause 100, wherein at least some of theplurality of striation bands extend away from the top surface to definea textured top surface area.

Clause 104. The foam article of clause 100, wherein the striation bandsextend inwardly at least 5 millimeters from the outer perimeter surface.

Clause 105. The foam article of clause 100, wherein the striation bandsextend inwardly at least 10 millimeters from the outer perimetersurface.

Clause 106. The foam article of clause 100, wherein the striation bandsextend inwardly at least 15 millimeters from the outer perimetersurface.

Clause 107. The foam article of clause 100, wherein the striation bandsextend inwardly at least 20 millimeters from the outer perimetersurface.

Clause 108. The foam article according to any one of clauses 94-107,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 109. A foam article, comprising: a foamed component, thecomponent comprising a foam volume comprising a foam core and anintegrally formed surface skin surrounding the foam core, the skindefining an outer side wall, a top surface and a bottom surface, and anouter perimeter edge at the intersection of the outer side wall and thetop surface, wherein the surface skin on at least one of the outer sidewall, top surface and bottom surface has a thickness of between 0.3millimeters and 1.0 millimeters.

Clause 110. The foam article of clause 109, wherein the skin on each ofthe outer side wall, the top surface and the bottom surface has athickness of between 0.3 millimeters and 1.0 millimeters.

Clause 111. The foam article of clause 110, wherein the density of thefoamed component is between 0.16 and 0.20 grams per cubic centimeter.

Clause 112. The foam article of clause 111, wherein the componentcomprises an open cell foam encased by the surface skin.

Clause 113. The foam article of clause 110, wherein the density of thefoamed component is between 0.17 and 0.19 grams per cubic centimeter.

Clause 114. The foam article of clause 109, wherein the skin on each ofthe outer side wall, the top surface and the bottom surface has athickness of between 0.6 millimeters and 0.8 millimeters.

Clause 115. The foam article of clause 110, wherein the energyefficiency of the foamed component is between 70 percent and 80 percent.

Clause 116. The foam article of clause 111, wherein the foam article isa cushioning element in the form of a midsole for an article offootwear.

Clause 117. The foam article of clause 116, further comprising anoutsole and a strobel coupled to the midsole.

Clause 118. The foam article of clause 117, wherein the energyefficiency of the combined midsole, outsole and strobel is between 65percent and 75 percent.

Clause 119. The foam article according to any one of clauses 109-118,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 120. A foam article, comprising: a foamed component having aratio of energy efficiency to energy intensity (EE/EI) greater than 1.5.

Clause 121. The foam article of clause 120, wherein the foamed componenthas an EE/EI greater than 1.7.

Clause 122. The foam article of clause 121, wherein the foamed componentis a midsole.

Clause 123. The foam article of clause 120, further comprising anoutsole and a strobel coupled to the midsole.

Clause 124. The foam article according to any one of clauses 120-123,wherein the foamed component comprises: a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 125. A foam article, comprising: a foamed component having aratio of energy efficiency to the product of energy intensity anddensity (EE/EI*ρ) value greater than 7.

Clause 126. The foam article of clause 125, wherein the foamed componenthas an EE/EI*ρ value greater than 9.

Clause 127. The foam article of clause 125, wherein the foamed componentis a midsole.

Clause 128. The foam article of clause 127, further comprising anoutsole and a strobel coupled to the midsole.

Clause 129. The foam article according to any one of clauses 125-128,wherein the foamed component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 130. A midsole for an article of footwear, comprising: a foamcomponent, the component comprising a profile defined by an outer sidewall, the component having a top surface and a bottom surface, thecomponent having a toe area, mid-foot area and heel area, wherein theouter side wall in the toe area has opposed curves each having a curveapex, and wherein a line intersecting the opposing curve apexesrepresents an intersection axis; and the component further comprising afirst injection gate vestige on a first side of the intersection axisand a second injection gate vestige on a second side of the intersectionaxis, wherein foam from the first injection gate vestige and foam fromthe second injection gate vestige form a flow boundary; and wherein theflow boundary intersects the intersection axis at two locations.

Clause 131. The midsole for an article of footwear of clause 130,wherein the flow boundary is nearer the second injection gate vestigethan the first injection gate vestige.

Clause 132. The midsole for an article of footwear of clause 131,wherein the article of footwear has a toe end, and wherein the firstinjection gate vestige is nearer the toe end than the second injectiongate vestige.

Clause 133. The midsole for an article of footwear according to any oneof clauses 130-132, wherein the midsole for an article of footwearcomprises a thermoplastic elastomeric composition according to any oneof clauses 1-53, a thermoplastic elastomeric composition comprising athermoplastic polyester homopolymer, a thermoplastic elastomericcomposition comprising a thermoplastic copolyester having two differenttypes of polyester monomeric segments, or a combination thereof.

Clause 134. A foam article, comprising: a foamed component having aratio of energy return to energy intensity (ER/EI) greater than 9,500.

Clause 135. The foam article of clause 134, wherein the foamed componenthas an ER/EI greater than 10,000.

Clause 136. The foam article of clause 134, wherein the foamed componentis a midsole.

Clause 137. The foam article of clause 136, further comprising anoutsole and a strobel coupled to the midsole.

Clause 138. A foam article, comprising: a foam component having a ratioof energy return to the product of energy intensity and density(ER/(EI*ρ)) value greater than 45,000.

Clause 139. The foam article of clause 138, wherein the foam componenthas an EE/(EI*ρ) value greater than 50,000.

Clause 140. The foam article of clause 138, wherein the foam componentis a midsole.

Clause 141. The foam article of clause 140, further comprising anoutsole and a strobel coupled to the midsole.

Clause 142. The foam article according to any one of clauses 138-140,wherein the foam component comprises a thermoplastic elastomericcomposition according to any one of clauses 1-53, a thermoplasticelastomeric composition comprising a thermoplastic polyesterhomopolymer, a thermoplastic elastomeric composition comprising athermoplastic copolyester having two different types of polyestermonomeric segments, or a combination thereof.

Clause 143. A method for making a foam article, the method comprising:forming a mixture of molten thermoplastic elastomer composition and afoaming agent; injecting the mixture into a mold cavity; causing afoaming of said mixture to form a foam article having a microcellularfoam structure; and removing the foam article from the mold cavity.

Clause 144. The method of clause 143, wherein the injection stepcomprises injecting the mixture through a plurality of injection gates.

Clause 144.1. The method of clause 143, wherein the injection stepcomprises injecting the mixture through a single injection gate.

Clause 145. The method of clause 144, wherein the foam article has anarticle volume comprising a plurality of sub-volumes, the method furthercomprising determining an aspect ratio for each of the plurality ofsub-volumes, the method further comprising designing the mold cavitysuch that the aspect ratio for each of the plurality of sub-volumes isgreater than 2.7.

Clause 146. The method of clause 145, further comprising designing themold cavity such that the aspect ratio for each of the plurality ofsub-volumes is greater than 3.0.

Clause 147. The method of clause 146, further comprising designing themold cavity such that the aspect ratio for each of the plurality ofsub-volumes is greater than 2.7.

Clause 148. A foam article, made by a process comprising the steps ofany of clauses 143-146.

Clause 149. The foam article according to clause 148, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 150. A midsole, made by a process comprising the steps of any ofclauses 143-149.

Clause 151. The midsole according to clause 150, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 152. A method for making a foam article, the method comprising:forming a mixture of molten thermoplastic elastomer composition and afoaming agent; injecting the mixture into a mold cavity through aplurality of injection gates; foaming the molten polymeric materialthereby forming a foam article having a microcellular foam structure;and removing the foam article from the mold cavity.

Clause 153. The method of clause 152, further comprising forming a gatevestige for each of the plurality of injection gates during the foamingstep.

Clause 154. The method of clause 153, further comprising designing themold with an axis formed by a first gate vestige of the plurality ofgate vestiges and a second gate vestige of the plurality of gatevestiges, and at least a third gate vestige of the plurality of gatevestiges offset from the gate vestige axis.

Clause 155. The method of clause 154, further comprising designing themold with at least a fourth gate vestige of the plurality of vestigesoffset from the gate vestige axis.

Clause 156. The method of clause 155, further comprising designing themold with the third gate vestige and the fourth gate vestige orthogonalto the gate vestige axis.

Clause 157. A foam article, made by a process comprising the steps ofany of clauses 152-156.

Clause 158. The foam article according to clause 157, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 159. A midsole, made by a process comprising the steps of any ofclauses 152-157.

Clause 160. The midsole according to clause 159, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 161. A method for making a foam article, the method comprising:forming a mixture of molten thermoplastic elastomer composition and afoaming agent; injecting the mixture into a mold cavity through aplurality of injection gates; foaming the molten polymeric materialthereby forming a foam article having an interior microcellular foamstructure with a closed surface skin with a thickness of between 0.3millimeters and 1.0 millimeters; and removing the foam article from themold cavity.

Clause 162. A foam article, made by a process comprising the steps ofclause 161.

Clause 163. The foam article according to clause 162, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 164. A midsole, made by a process comprising the steps of clause161.

Clause 165. The midsole according to clause 164, wherein thethermoplastic elastomer composition comprises: a thermoplasticelastomeric composition according to any one of clauses 1-53, athermoplastic elastomeric composition comprising a thermoplasticpolyester homopolymer, a thermoplastic elastomeric compositioncomprising a thermoplastic copolyester having two different types ofpolyester monomeric segments, or a combination thereof.

Clause 166. An article of footwear comprising a foam article accordingto any one of clauses 54-129, 134-142, 157-158, 162-163.

Clause 167. A method of manufacturing a foamed polymer article, themethod comprising: grinding recycled thermoplastic polyester elastomercomposition into a ground recyclate material; mixing a metered amount ofthe ground recyclate material and a virgin polymer material of virginthermoplastic polyester elastomer composition into a mixed batch, themetered amount being about 20% by mass or less of a total mass of themixed batch; melting the ground recyclate material and the virginpolymer material into a polymer melt composition; adding a physicalfoaming agent to the polymer melt composition; injecting the polymermelt composition with the physical foaming agent into an internal cavityof a mold tool; activating the physical foaming agent such that thephysical foaming agent causes the polymer melt composition to expand andfill the internal cavity of the mold tool to form the foamed polymerarticle; and removing the formed foamed polymer article from the moldtool.

Clause 167. The method of clause 166, wherein the recycled thermoplasticpolyester elastomer composition includes scrap material recovered froman extruded batch of un-foamed thermoplastic polyester elastomercomposition or scrap material recovered from an injection molded batchof foamed thermoplastic polyester elastomer composition, or both.

Clause 168. The method of clauses 166 or 167, wherein the recycledthermoplastic polyester elastomer composition is derived from one ormore reactants comprising a poly(alkylene oxide)diol material or anaromatic dicarboxylic acid material, or both.

Clause 169. The method of any one of clauses 166 to 168, wherein thephysical foaming agent is added by injecting the physical foaming agentinto the polymer melt composition while the polymer melt composition iscontained in an injection barrel of an injection molding system.

Clause 170. The method of any one of clauses 166 to 169, wherein thephysical foaming agent includes a super critical fluid comprising asupercritical nitrogen or a supercritical carbon dioxide, or both.

Clause 171. The method of any one of clauses 166 to 170, wherein themixed batch of the ground recyclate material and the virgin polymermaterial has a set point temperature ranging from about 150° C. to about265° C.

Clause 172. The method of any one of clauses 166 to 171, wherein themixed batch of the ground recyclate material and the virgin polymermaterial has an average peak crystallization temperature ranging fromabout 90° C. to about 190° C.

Clause 173. The method of any one of clauses 166 to 172, wherein theformed foamed polymer article has a cell size average of about 0.1 mm toabout 2.0 mm.

Clause 174. The method of any one of clauses 166 to 173, wherein theformed foamed polymer article has: a ratio of energy efficiency toenergy intensity that is greater than about 1.3; a ratio of energyefficiency to the product of energy intensity and density that isgreater than about 5.9; a ratio of energy return to energy intensitythat is greater than about 7,225; and/or a ratio of energy return to theproduct of energy intensity and density that is greater than about38,250.

Clause 175. The method of any one of clauses 166 to 174, wherein therecycled thermoplastic polyester elastomer has a weight averagemolecular weight ranging from about 50,000 Daltons to about 200,000Daltons.

Clause 176. The method of any one of clauses 166 to 175, wherein addingthe physical foaming agent to the polymer melt composition includesdissolving a supercritical fluid into the polymer melt composition underpressure to form a single-phase solution (SPS).

Clause 177. The method of clause 176, wherein activating the physicalfoaming agent includes releasing the pressure to expand thesupercritical fluid.

Clause 178. The method of any one of clauses 166 to 177, furthercomprising receiving a recyclate batch of the recycled thermoplasticpolyester elastomer composition.

Clause 179. The method of clause 178, wherein receiving the recyclatebatch includes obtaining, from a sprue, a runner, and/or a gate of aninjection molding system, scrap segments of a prior-foamed polymerarticle formed from a prior mixed batch of the ground recyclate materialand the virgin polymer material.

Clause 180. The method of any one of clauses 166 to 179, wherein theground recyclate material has an irregular shape with a major lengththat is about 1 mm to about 10 mm, and the virgin polymer material has apellet size of about 1 mm to about 10 mm.

Clause 181. The method of any one of clauses 166 to 180, wherein meltingthe ground recyclate material and the virgin polymer material includesmelting the mixed batch into the polymer melt composition.

Clause 182. A method of manufacturing a foamed polymer article, themethod comprising: grinding a recyclate batch of recycled thermoplasticpolyester elastomer composition into a ground recyclate material;combining a metered amount of the ground recyclate material and a virginpolymer material of virgin thermoplastic polyester elastomer compositioninto a mixed batch; melting the ground recyclate material and the virginpolymer material into a polymer melt composition; adding a physicalfoaming agent to the polymer melt composition; injecting the polymermelt composition with the physical foaming agent into an internal cavityof a mold tool; activating the physical foaming agent such that thephysical foaming agent causes the polymer melt composition to expand andfill the internal cavity of the mold tool to form the foamed polymerarticle; and removing the formed foamed polymer article from the moldtool, wherein the formed foamed polymer article has: a ratio of energyefficiency to energy intensity that is greater than about 1.3; a ratioof energy efficiency to the product of energy intensity and density thatis greater than about 5.9; a ratio of energy return to energy intensitythat is greater than about 7,225; and/or a ratio of energy return to theproduct of energy intensity and density that is greater than about38,250.

Clause 183. A method of producing a foamed polymer article, the methodcomprising: injecting a mixed thermoplastic resin into a mold, the mixedthermoplastic resin comprising a mixture of a virgin thermoplasticcomposition resin and a recycled thermoplastic composition resin; andfoaming the mixed thermoplastic composition resin within an internalmold cavity of a molding system to form the foamed polymer article,wherein a mass of the recycled thermoplastic composition resin withinthe mixed thermoplastic composition resin is at least about 20% by massof a total mass of the mixed thermoplastic composition resin.

Clause 184. A method of manufacturing a foamed polymer article, themethod comprising: adding a physical foaming agent to a polymer meltcomposition, the polymer melt composition including a blend of arecyclate polymer material and a virgin polymer material of virginthermoplastic polyester elastomer composition, the recyclate polymermaterial being about 20% by mass or less of a total mass of the polymermelt composition; injecting the polymer melt composition with thephysical foaming agent into an internal cavity of a mold tool;activating the physical foaming agent such that the physical foamingagent causes the polymer melt composition to expand and fill theinternal cavity of the mold tool to form the foamed polymer article; andremoving the formed foamed polymer article from the mold tool.

Clause 185. A method of producing a foamed sole component of a shoe, themethod comprising: injecting a mixed thermoplastic composition resininto a mold, the mixed thermoplastic composition resin comprising amixture of a virgin thermoplastic composition resin and a recycledthermoplastic composition resin, and the mold comprising a sole cavityportion fluidly coupled to a filling portion; and foaming the mixedthermoplastic composition resin within the sole cavity portion to formthe foamed sole component of the shoe, wherein a mass of the recycledthermoplastic composition resin within the sole cavity portion isgreater than or equal to a mass of the mixed thermoplastic compositionresin within the filling portion.

Clause 186. The method of clause 185, further comprising: regrinding,prior to injecting the mixed thermoplastic composition resin into themold, a prior-foamed shot of the mixed thermoplastic composition resinretrieved from the filling portion to form the recycled thermoplasticcomposition resin; and mixing the recycled thermoplastic compositionresin with the virgin thermoplastic composition resin to form the mixedthermoplastic composition resin.

Clause 187. The method of clauses 185 or 186, wherein the foamed solecomponent has an energy return measurement that is within a predefinedtolerance of an energy return measurement of a comparable shoe solecomponent formed solely from the virgin thermoplastic composition resin.

Clause 188. The method of clause 187, wherein the predefined toleranceis about 75% to about 99% of the energy return measurement of thecomparable shoe sole component, the foamed sole component and thecomparable shoe sole component sharing a comparable shape, size, and/ormethod of molding.

Clause 189. The method of any one of clauses 186 to 188, wherein apercent by mass of the recycled thermoplastic composition resin withinthe mixed thermoplastic composition resin is between about 1% and about20%.

Clause 190. The method of any one of clauses 185 to 189, wherein foamingthe mixed thermoplastic composition resin comprises: dissolving asupercritical fluid into the mixed thermoplastic resin under pressure toform an SPS; and venting, after dissolving the supercritical fluid, thepressure to release the supercritical fluid from the SPS.

Clause 191. The method of any one of clauses 185 to 190, wherein thefilling portion of the mold comprises at least one cold runner.

Clause 192. The method of clause 191, wherein the mold further comprisesat least one hot runner.

Clause 193. The method of any one of clauses 185 to 192, wherein thefilling portion includes one or more channels that direct a flow of themixed thermoplastic composition resin from a nozzle or hot runner of aninjection molding apparatus to the sole cavity portion of the mold.

Clause 194. The method of any one of clauses 185 to 193, wherein themass of the recycled thermoplastic composition resin within the solecavity portion is approximately equal to the mass of the mixedthermoplastic composition resin within the filling portion.

Clause 195. The method of any one of clauses 185 to 194, wherein thevirgin thermoplastic composition resin comprises a thermoplasticpolyester elastomer composition.

Clause 196. An article of footwear comprising: an upper configured toreceive a foot of a user; and a sole structure attached to the upper andconfigured to support thereon the foot of the user, the sole structuredefining a ground-engaging portion of the footwear, the sole structureincluding a foamed sole component, wherein the foamed sole componentincludes a recyclate material of recycled thermoplastic polyesterelastomer composition and a virgin material of virgin thermoplasticpolyester elastomer composition, the recyclate material being about 20%by mass or less of a total mass of the foamed sole component.

Clause 197. The article of footwear of clause 196, wherein the recycledthermoplastic polyester elastomer composition includes scrap materialrecovered from an extruded batch of un-foamed thermoplastic polyesterelastomer composition or scrap material recovered from an injectionmolded batch of foamed thermoplastic polyester elastomer composition, orboth.

Clause 198. The article of footwear of clauses 196 or 197, wherein therecycled thermoplastic polyester elastomer composition is derived fromone or more reactants comprising a poly(alkylene oxide)diol material oran aromatic dicarboxylic acid material, or both.

Clause 199. The article of footwear of any one of clauses 196 to 198,wherein the foamed sole component has a cell size average of about 0.18mm to about 0.58 mm.

Clause 200. The article of footwear of any one of clauses 196 to 199,wherein the foamed sole component has: a ratio of energy efficiency toenergy intensity that is greater than about 1.3; a ratio of energyefficiency to the product of energy intensity and density that isgreater than about 5.9; a ratio of energy return to energy intensitythat is greater than about 7,225; and/or a ratio of energy return to theproduct of energy intensity and density that is greater than about38,250.

Clause 201. The article of footwear of any one of clauses 196 to 200,wherein the recycled thermoplastic polyester elastomer has a weightaverage molecular weight ranging from about 50,000 Daltons to about200,000 Daltons.

Clause 202. The article of footwear of any one of clauses 196 to 201,wherein the recycled thermoplastic polyester elastomer is a blockcopolymer, a segmented copolymer, a random copolymer, and/orcondensation copolymer having a weight average molecular weight of about50,000 Daltons to about 200,000 Daltons.

Clause 203. An article of footwear comprising: an upper configured toreceive a foot of a user; and a sole structure attached to the upper andconfigured to support thereon the foot of the user, the sole structuredefining a ground-engaging portion of the footwear, the sole structureincluding a foamed sole component, wherein the foamed sole component hasa melting temperature of at least about 190° C. and an average peakcrystallization temperature of at least about 135° C.

Clause 204. A method of producing foamed polymer articles, comprising:forming a run of the foamed polymer articles having an average articlemass m_(AA) of the foamed polymer articles per run and an article defectrate DA per run; retrieving a batch of a manufacturing byproductincidental to the run of the foamed polymer articles, the manufacturingbyproduct having an average byproduct mass m_(AB) per run; andretrieving a lot of defective articles incidental to the run of thefoamed polymer articles, the defective articles having an average defectmass m_(AD) per run, wherein the average defect mass m_(AD) is themathematical product of the article defect rate {dot over (D)}_(A) andthe average article mass m_(AA), and wherein (m_(AB)+m_(AD))/m_(AA)≤0.2.

Clause 205. The method of clause 204, wherein forming the run of thefoamed polymer articles includes molding a first run of a first numberof first polymer articles having a first shape and size, and molding asecond run of a second number of second polymer articles having a secondshape and size distinct in shape and/or size from the first polymerarticles.

Clause 206. The method of clause 205, wherein the average article massm_(AA) includes a first average article mass m_(AA−1) per run for thefirst run of the first polymer articles and a second average articlemass m_(AA−2) per run for the second run of the second polymer articles.

Clause 207. The method of clauses 205 or 206, wherein the article defectrate DA per run includes a first article defect rate {dot over(D)}_(A-1) per run for the first run of the first polymer articles and asecond article defect rate {dot over (D)}_(A-2) per run for the secondrun of the second polymer articles.

Clause 208. The method of any one of clauses 205 to 207, wherein theaverage byproduct mass m_(AB) includes a first average byproduct massm_(AB−1) incidental to the first run and a second average byproduct massm_(AB−2) incidental to the second run.

Clause 209. The method of any one of clauses 205 to 208, wherein theaverage byproduct mass m_(AB) is a mathematical sum of: (1) a firstbyproduct mass m_(B-1) incidental to the first run divided by the firstnumber of the first polymer articles; and (2) a second byproduct massm_(B-2) incidental to the second run divided by the second number of thesecond polymer articles.

Clause 210. The method of any one of clauses 205 to 209, wherein theaverage defect mass m_(AD) includes a first average defect mass m_(AD−1)incidental to the first run and a second average defect mass m_(AD−1)incidental to the second run.

Clause 211. The method of any one of clauses 205 to 210, wherein formingthe run of the foamed polymer articles includes injection molding thefoamed polymer articles using a tooling assembly, and wherein theaverage byproduct mass m_(AB) per run includes a first average byproductmass m_(AB′) of the manufacturing byproduct upstream from the toolingassembly and a second average byproduct mass m_(AB″) of themanufacturing byproduct downstream from the tooling assembly.

Clause 212. The method of any one of clauses 205 to 211, furthercomprising forming a second run of the foamed polymer articles utilizingat least a portion of the batch of manufacturing byproduct and/or atleast a portion of the lot of defective articles.

What is claimed is:
 1. A foam article for a component of footwear, thefoam article comprising: an outer surface comprising a plurality ofinjection gate vestiges; and a foam article volume comprising aplurality of sub-volumes, each sub-volume being associated with one ofthe plurality of injection gate vestiges; wherein an aspect ratio foreach of the plurality of sub-volumes is greater than 2.7.
 2. The foamarticle of claim 1, wherein a first gate vestige and a second gatevestige of the plurality of gate vestiges define a gate vestige axis,and at least a third gate vestige of the plurality of gate vestiges isoffset from the gate vestige axis.
 3. The foam article of claim 2,wherein the plurality of gate vestiges further comprises a fourth gatevestige that is offset from the gate vestige axis.
 4. The foam articleof claim 3, wherein the third gate vestige and the fourth gate vestigeare orthogonal to the gate vestige axis.
 5. The foam article of claim 1,wherein the volume comprises an interior microcellular foam structureand the outer surface comprises a closed surface skin with a thicknessof between 0.3 millimeters and 1.0 millimeters.
 6. The foam article ofclaim 1, wherein the foam article is formed by: forming a mixture ofmolten thermoplastic elastomer composition and a foaming agent;injecting the mixture into a mold cavity through a plurality ofinjection gates; causing a foaming of said mixture to form the foamarticle with a microcellular foam structure; and removing the foamarticle from the mold cavity.
 7. The foam article of claim 6, whereineach of the plurality of injection gate vestiges is associated with oneof each of the plurality of injection gates, and the plurality of gatevestiges is formed during the caused foaming.
 8. The foam article ofclaim 7, wherein each of the sub-volumes is substantially formed fromthe mixture injected through its corresponding injection gate.
 9. Amethod for making a foam article for a component of footwear, the methodcomprising: forming a mixture of molten thermoplastic elastomercomposition and a foaming agent; injecting the mixture into a moldcavity of a mold comprising a plurality of injection gates; causing afoaming of said mixture to form a foam article having a microcellularfoam structure; and removing the foam article from the mold cavity;wherein: the foam article comprises a volume having a plurality ofsub-volumes, with each sub-volume being associated with one of theplurality of injection gates; and each sub-volume has an aspect ratio ofgreater than 2.7.
 10. The method of claim 9, wherein the injection stepcomprises injecting the mixture through the plurality of injectiongates.
 11. The method of claim 10, wherein each of the sub-volumes issubstantially formed from the mixture injected through its correspondinginjection gate.
 12. The method of claim 9, further comprising forming agate vestige for each of the plurality of injection gates during thecaused foaming.
 13. The method of claim 8, wherein the causing thefoaming the molten polymeric material further comprises forming a foamarticle with an interior microcellular foam structure with a closedsurface skin with a thickness of between 0.3 millimeters and 1.0millimeters.
 14. A method for making a foam article for a component offootwear, the method comprising: forming a mixture of moltenthermoplastic elastomer composition and a foaming agent; injecting themixture into a mold cavity of a mold, the mold comprising a plurality ofinjection gates, including a first injection gate and second injectiongate defining an injection gate axis, and at least a third injectiongate offset from the injection gate axis; causing a foaming of saidmixture to form a foam article having a microcellular foam structure;and removing the foam article from the mold cavity.
 15. The method ofclaim 14, wherein the injection step comprises injecting the mixturethrough the plurality of injection gates,
 16. The method of claim 15further comprising forming a gate vestige for each of the plurality ofinjection gates during the caused foaming.
 17. The method of claim 14,wherein the mold further comprises at least a fourth injection gateoffset from the gate vestige axis.
 18. The method of claim 17, whereinthe third injection gate and the fourth injection gate are orthogonal tothe gate vestige axis.
 19. The method of claim 14, wherein the causingthe foaming the molten polymeric material further comprises forming afoam article with an interior microcellular foam structure with a closedsurface skin with a thickness of between 0.3 millimeters and 1.0millimeters.
 20. The method of claim 15, wherein the foam articlecomprises a volume having a plurality of sub-volumes, with eachsub-volume being associated with one of the plurality of injectiongates; wherein each sub-volume has an aspect ratio of greater than 2.7.